Friction effects during a progressive microforming process for production of micropins of various diameters were experimentally investigated and were analytically modeled, using a hybrid friction model. The response surface method and ANOVA analysis were used to generalize the findings for various pin diameters. Besides, it was shown that to get an accurate result in simulation, the friction model must be considered locally instead of a global friction model for the whole process. The effect of friction factor on the final micropart dimensions (the effect on the instantaneous location of the neutral plane) and the forming pressure were investigated. The results showed a reduction in the friction factor as die diameter increased. Following that, the optimum frictional condition to obtain the highest micropart aspect ratio was defined as the maximum friction on the interface between the die upper surface and the punch surface, together with a minimum friction inside the die orifice.
Experimental and Simulation of Friction Effects in an Open-Die Microforging/Extrusion Process
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received January 9, 2013; final manuscript received January 13, 2014; published online February 12, 2014. Assoc. Editor: Ulf Engel.
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Ghassemali, E., Tan, M., Chao Voon Lim, S., Beng Wah, C., and Wollmar Jarfors, A. E. (February 12, 2014). "Experimental and Simulation of Friction Effects in an Open-Die Microforging/Extrusion Process." ASME. J. Micro Nano-Manuf. March 2014; 2(1): 011005. https://doi.org/10.1115/1.4026518
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