Development of warm micro ultra deep drawing process based on blank material flow control with press motion and ultra high fluid pressure

• Project/Area Number: 26630369
• Research Category: Grant-in-Aid for Challenging Exploratory Research
• Allocation Type: Multi-year Fund
• Research Field: Material processing/Microstructural control engineering
• Research Institution: Tokyo Metropolitan University
• Principal Investigator: MANABE Ken-ichi 首都大学東京, 理工学研究科, 教授 (10145667)
• Co-Investigator(Kenkyū-buntansha): FURUSHIMA TSUYOSHI 首都大学東京, 大学院理工学研究科, 助教 (30444938)
• Project Period (FY): 2014-04-01 – 2016-03-31
• Project Status: Completed (Fiscal Year 2015)
• Budget Amount: ¥4,030,000 (Direct Cost: ¥3,100,000、Indirect Cost: ¥930,000); Fiscal Year 2015: ¥1,430,000 (Direct Cost: ¥1,100,000、Indirect Cost: ¥330,000); Fiscal Year 2014: ¥2,600,000 (Direct Cost: ¥2,000,000、Indirect Cost: ¥600,000)
• Keywords: マイクロフォーミング / 対向液圧深絞り / マイクロ超深絞り / 超高圧 / プレスモーション / 逐次成形 / 材料流動制御 / 再絞り / 超深絞り / 逐次変形 / FEM / 寸法効果

Outline of Final Research Achievements

The goal of study is to challenge in the development of a new warm micro-ultra-deep drawing (MUDD) process based on servo press motion control combining the hydro-mechanical pressure effect of ultra-high fluid pressure and the redrawing. In this study, the new fabrication principle of MUDD process is proposed, in which after redrawing, incremental deformation and material flow by press motion and ultra high fluid pressure can produce a high aspect ratio drawn cup. For the experimental confirmation, a high-performance MUDD system was developed with ultra-high pressure up to 400 MPa. In the simulation, MUDD process for the slenderness ratio 10 or more has achieved in case of a dynamic process. Even if there is no dynamic effect, a drawn cup of diameter 0.56mm and the slenderness ratio of about 5 is successful in FEM. In the experimental verification, a stainless steel SUS304 drawn cup with 0.5mm diameter and its slenderness ratio of 0.9 is successful in the MUDD process.

Research Products

• [Journal Article] Tribological behavior in micro-sheet hydroforming (2016)
  • Author(s): Hideki Sato, Ken-ichi Manabe, Dongbin Wei, Zhengyi Jiang, Sergei Alexandrov
  • Journal Title: Tribology International Volume: 97 Pages: 302-312
  • DOI: 10.1016/j.triboint.2016.01.041
  • Peer Reviewed / Open Access / Int'l Joint Research
• [Journal Article] マイクロ対向液圧深絞りにおける変形挙動に及ぼす相対工具寸法の効果 (2016)
  • Author(s): 佐藤英樹、真鍋健一、Dongbin Wei, Zhengyi Jiang
  • Journal Title: 塑性と加工 Volume: 57
  • NAID: 130005165593
  • Peer Reviewed / Int'l Joint Research
• [Journal Article] Micro Sheet Hydroforming Process of Ultra-Thin Pure Titanium Foil (2015)
  • Author(s): Hideki Sato, Ken-ichi Manabe, Dongbin Wei, Zhengyi Jiang and Daiki Kondo
  • Journal Title: Key Engineering Materials Volume: 626 Pages: 397-401
  • DOI: 10.4028/www.scientific.net/kem.626.397
  • Peer Reviewed / Open Access
• [Journal Article] Potential of fluid pressure use for achieving high formability in micro sheet forming process (2014)
  • Author(s): Hideki Sato, Ken-ichi Manabe, Dongbin Wei, Zhengyi Jiang, and Daiki Kondo
  • Journal Title: AIP Conference Proceedings Volume: 1618 Pages: 327-330
  • DOI: 10.1063/1.4897740
  • Peer Reviewed / Open Access
• [Journal Article] Formability of Micro Sheet Hydroforming of Ultra-fine Grained Stainless Steel (2014)
  • Author(s): Hideki Sato, Ken-ichi Manabe, Daiki Kondo, Dongbin Wei, Zhengyi Jiang
  • Journal Title: Procedia Engineering Volume: 81 Pages: 1416-1468
  • DOI: 10.1016/j.proeng.2014.10.174
  • Peer Reviewed / Open Access
• [Presentation] 超高圧とパンチモーションとの逐次制御によるマイクロ超探絞り過程における適正加工条条件の有限要素解析 (2015)
  • Author(s): 眞野峻行、佐藤英樹、近藤大輝、真鍋健一
  • Organizer: 第66回塑性加工連合講演会
  • Place of Presentation: 福島県、いわき市
  • Year and Date: 2015-10-29
• [Presentation] FEM-base Investigation of Micro Ultra-Deep Drawing (2015)
  • Author(s): Takayuki Mano, Hideki Sato, Daiki Kondo, Ken-ichi Manabe
  • Organizer: The Asian Workshop on Micro/Nano Forming Technology(国際会議)
  • Place of Presentation: Nagano, Japan
  • Year and Date: 2015-10-14
• [Presentation] Numerical Study of Micro Hydro Deep Drawing (2015)
  • Author(s): Liang Luo, Zhengyi Jiang, Dongbin Wei,Xianming Zhao, Di Wu Ken-ichi Manabe, Hideki Sato
  • Organizer: The 7th International Conference of Tube Hydroforming(国際会議)
  • Place of Presentation: Xian, China
  • Year and Date: 2015-09-09
• [Presentation] Numerical and Experimental Investigation of Cross Shaped Micro Tube Hydroforming (2015)
  • Author(s): Hideki Sato, Dai Kobayashi, Ken-ichi Manabe
  • Organizer: The 7th International Conference of Tube Hydroforming(国際会議)
  • Place of Presentation: Xian, China
  • Year and Date: 2015-09-09
• [Presentation] Study on Micro Extra Deep Drawing Process with Ultrahigh Fluid Pressure and Press Control (2015)
  • Author(s): Hideki Sato, Daiki Kondo, Ken-ichi Manabe, Kuniyoshi Ito
  • Organizer: The 4th International Conference on New Forming Technology (国際会議)
  • Place of Presentation: Scotland, UK
  • Year and Date: 2015-08-06
• [Presentation] 超高圧とパンチモーションとの逐次制御によるマイクロ超深絞りのFEMシミュレーション (2015)
  • Author(s): 佐藤英樹、近藤大輝、眞野峻行、真鍋健一
  • Organizer: 平成27年度塑性加工春季講演会
  • Place of Presentation: 神奈川県,横浜市
  • Year and Date: 2015-05-29
• [Presentation] Development of Triple Action Servo Press Machine for Micro Hydromechaqnical Deep Drawing (2014)
  • Author(s): D. Kondo, H. Sato, K. Manabe
  • Organizer: th Asian Workshop on Micro/ Nano Forming Technology
  • Place of Presentation: Taipei, Taiwan
  • Year and Date: 2014-11-09 – 2014-11-12
• [Presentation] Numerical Study on Geometrical Size Effect in Micro Sheet Hydroforming (2014)
  • Author(s): H. Sato, K. Manabe, D. Wei, Z. Jiang
  • Organizer: 7th Asian Workshop on Micro/ Nano Forming Technology
  • Place of Presentation: Taipei, Taiwan
  • Year and Date: 2014-11-09 – 2014-11-12
• [Presentation] Formability of Micro Sheet Hydroforming of Ultra-Fine Grained Stainless Steel (2014)
  • Author(s): Hideki Sato, Ken-ichi Manabe, Daiki Kondo, Dongbin Wei, Zhengyi Jiang
  • Organizer: 11th International Conference on Technology of Plasticity, ICTP 2014
  • Place of Presentation: Nagoya Congress Center, Nagoya, Japan
  • Year and Date: 2014-10-19 – 2014-10-24
• [Presentation] マイクロシートハイドロフォーミングにおける板厚スケール因子の効果 (2014)
  • Author(s): 佐藤英樹、真鍋健一
  • Organizer: 第65回塑性加工連合講演会
  • Place of Presentation: 岡山大学
  • Year and Date: 2014-10-11 – 2014-10-13
• [Presentation] トリプルアクションサーボ式マイクロ対向液圧深絞り装置の開発 (2014)
  • Author(s): 近藤大輝、佐藤英樹、真鍋健一、伊藤國吉
  • Organizer: 第65回塑性加工連合講演会
  • Place of Presentation: 岡山大学
  • Year and Date: 2014-10-11 – 2014-10-13
• [Presentation] 微細粒鋼のマイクロ対向液圧深絞りにおける成形特性 (2014)
  • Author(s): 佐藤英樹、真鍋健一
  • Organizer: 第65回塑性加工連合講演会
  • Place of Presentation: 岡山大学
  • Year and Date: 2014-10-11 – 2014-10-13
• [Presentation] Micro Sheet Hydroforming Process of Ultra-Thin Pure Titanium Foil (2014)
  • Author(s): Sato, H., Manabe, K., Wei, D., Jiang, Z., Kondo, D
  • Organizer: 12th Asia-Pacific Conference on Engineering Plasticity and Its Applications (AEPA2014)
  • Place of Presentation: Kaohsiung, Taiwan
  • Year and Date: 2014-09-01 – 2014-09-05
• [Presentation] Experimental and Numerical Investigation of Micro Sheet Hydroforming of Stainless Steel Foil (2014)
  • Author(s): Sato, H., Manabe, K., Wei, D., Jiang, Z
  • Organizer: the ASME 2014 International Conference on Materials and Processing
  • Place of Presentation: Detroit, USA
  • Year and Date: 2014-06-09 – 2014-06-13