Optimization of axisymmetric open-die micro-forging/extrusion processes: An upper bound approach

• Optimization of a novel micro-open-die forging/extrusion processes.
• Physical phenomological studies of open-die forging/extrusion processes.
• Introducing geometry size factor in the modeling.
• Considering the effect of material flow inside the die during the process.
• Prediction of material behavior during and after the process.

There is a trend towards component miniaturization and strong drive towards cost effective and sustainable metal forming techniques of miniaturized components. This paper presents an upper bound solution for the optimization of open-die forging/extrusion processes in the forming of micro-pins from a sheet metal. Using such an analytical modeling approach, the critical blank thickness, the resulting final part geometry, together with the required forming load were predicted based on the location of the neutral plane under the punch during the process. Based on the phenomenological findings of the process, the geometry size factor, x, was introduced explaining its relative importance to the model. Experimental results obtained from C11000 copper samples using a progressive microforming process was found to agree well with the results predicted by the model. The results were also validated with other results reported before from a similar process.

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