Power and forming force relation on a solenoid actuated micro-forming machine.

With respect to the miniaturization of a materials processing, it is expected energy consumption is also proportionally miniaturized or reduced. The aim of this project was to analyze the feasibility of developing low power consumption micro sheet forming machine for the application of micro or thin sheet forming. A low energy miniaturized sheet forming machine was developed. The machine was tested with a view to quantify its performance in terms of behavior and relation of forming forces, forming speed with respect to the electrical energy consumed. Based on the preliminary tests, the machine demonstrated capability of producing around 320 Newton of force and the force decreases when travel distance increases. The machine also has capability to conduct the forming in milliseconds of time for one cycle. While all these tests were conducted at maximum 36V voltage and around 9 amp of current maximum, the energy consumption was only rated at 0.57 Watt-hour (Wh) for 10 parts per second operation. This is very low in terms of power consumption and seen as a feasible solution to address the energy consumption for micro sheet forming process application. Result on the study of energy consumption used to form. It is hence concluded that it was feasible to reduce power consumption by replacing high powered machineries for miniaturized low power forming machine to cater micro forming processes. [ABSTRACT FROM AUTHOR]