EXPERIMENTAL EVALUATION OF SIZE EFFECTS IN MICRO DEEP DRAWING PROCESS OF THIN FOIL MATERIALS.

Micro deep drawing of metallic cups is a cost effective technique if the parameters are suitably identified, but reducing dimensions increases the difficulties in manufacturing. In this work, formability study of pure copper foils and thickness distribution in micro deep drawing are carried out. The pure copper C1100 foil thickness of 100, 200 and 300 µm is selected and the limit drawing ratio is determined. In order to determine the forming depth in micro scale and force required in formed parts, a micro deep drawing tool assembly is developed. The results shows that 300 μm foil exhibits good formability in tensile test and Ericson cupping test. The excessive reduction in thickness specifically at the cup shoulder corner and the upper part of the side wall is located. The thinning is identified maximum at the side wall of the cup along the transverse direction. The results indicate that copper micro cups with high quality can be efficiently produced with appropriate forming parameters. [ABSTRACT FROM AUTHOR]