Simulations and experiments in punching spring-steel devices with sub-millimeter features

This work demonstrates the feasibility of meso-scale (100 μm to mm) punching of multiple holes of intricate shapes in metals. Analytical modeling, finite element (FE) simulation, and experimentation are used in this work. Two-dimensional FE simulations in ABAQUS were done with an assumed material modeling and plane-strain condition. A known analytical model was used and compared with the ABAQUS simulation results to understand the effects of clearance between the punch and the die. FE simulation in ABAQUS was done for different clearances and corner radii of the punch, die, and holder. To complement modeling with real experiments and for the purpose of comparison, a set of punches and dies were made to punch out a miniature spring-steel gripper. Comparison of compliant grippers made by wire-cut electro discharge machining (EDM) and punching shows that realizing sharp interior and re-entrant corners by punching is not easy to achieve. However, the promise of realizing meso-scale parts with complicated shapes through punching is demonstrated in this work; and further work is identified and some strategies are suggested for improvement. The main contribution of this paper is in adapting the well-established punching and blanking operations to the meso-scale as a viable alternative to making miniature devices currently dominated by lithography-based techniques.