Laser shock micro-bulk forming: Numerical simulation and experimental research

This study applies high rate forming technology to the manufacture of miniature parts and proposes a novel miniature parts bulk forming method, that is, laser shock micro-bulk forming (LSMBF). Through the numerical simulation and experimental research on 1100Al rod, the feasibility of manufacturing miniature parts using the LSMBF method is discussed. The similarities and differences of two simulation methods, namely, the smooth particle dynamics and finite element coupling (SPH-FE) and coupled Euler–Lagrangian (CEL) methods, were analyzed. Results show that the SPH-FE method is more consistent with the experiment and is more suitable for simulating the complex large deformation forming process of LSMBF than the CEL method. This study shows that the plastic deformation process of LSMBF is as follows. First, the upper end of the rod undergoes mushroom-shaped upsetting. Then, the bottom of the rod touches the micro die, and the upsetting phenomenon occurs. Finally, the micro-die is gradually filled. The plastic deformation of metal is related to the stress wave propagation and inertia effects. The main flow direction of the metal is axial, and the flow uniformity is fine. This study also shows that increasing the laser energy intensity is beneficial to improving the uniformity of the parts when impacting micro-die at high speed.