2013 Volume 7 Issue 2 Pages 251-263
The present study aims to clarify the scale dependency of progressive adhesion behavior of work material on micro tools under the dry friction in microforming. Scaled progressive deep drawing test up to 300 times is conducted under dry condition in micro- and milli- scale. The process dimensions of 0.97mm and 5.82mm in drawn cup diameter are produced with the stainless steel foils of 0.05mm and 0.3mm in thickness, respectively. The experimental results show that the transition of maximum punch force has different tendencies in each scale. These tendencies are well corresponded to the transition in surface state of tools and drawn cups. While, the strong adhesive wear is observed for the milli-scale, there is a slight change in the surface state of the tools for micro-scale. To investigate this difference in the adhesion behavior of the work material in each scale, a finite element analysis considering surface asperities is conducted. The distribution of the adhesion volume on the die corner radius is evaluated with a semi-empirical wear model in which is calculated with a function of normal pressure and relative velocity between blank and die. The results show the low adhesion volume in micro-scale, due to the short sliding distance during the process. The progressive adhesion behavior of work material and the advantage of tool life in micro-scale metal forming are demonstrated.