New Compound Forming Process of Roll-pressing and Stamping for Metal Foils with High Aspect Ratio Grooves

LI Ting; WEI Xiaoji; SHI Yongjie; XIAO Zhuo; ZHANG Chunmiao

doi:10.3969/j.issn.1674-6457.2025.09.023

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (9) : 233-240. DOI: 10.3969/j.issn.1674-6457.2025.09.023

New Compound Forming Process of Roll-pressing and Stamping for Metal Foils with High Aspect Ratio Grooves

LI Ting, WEI Xiaoji^*, SHI Yongjie, XIAO Zhuo, ZHANG Chunmiao

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Abstract

The work aims to innovatively design a novel roll-pressing composite forming process for high-aspect-ratio foil groove array features to address the pain points of the current roll-pressing process in metal foil processing, such as large draft angles and easy fracture during stamping and shaping. For the method, main and auxiliary roll-pressing dies with different dimensions were adopted, which only formed one groove feature of the metal foil simultaneously. During roll-pressing, the feed end of the metal foil was in a free material supplement stage, thereby achieving a low material thinning rate. In the stamping stage, the elastic resilience of the roll-pressed semi-finished product was used to realize self-positioning, which effectively improved positioning accuracy and enhanced material utilization. Forming tests were conducted on a 0.1 mm-thick metal foil, with the designed features being a groove depth of 2.2 mm, a ridge width of 3.1 mm, a valley width of 2.9 mm, and a total of 32 grooves. Inspection of the final finished product showed no dimensional deviation in the length and height directions, and the maximum material thinning rate was only 0.15%. Conclusions indicate that increasing the dimensional difference between the two roll-pressing dies can reduce the coincidence degree and the roll-pressing elongation rate of the metal foil; carrying out anti-interference design on the outer contours of the main and auxiliary rollers using mechanical auxiliary design software from both static and dynamic perspectives enables precise contour design of the roll-pressing dies; and the stamping die can adopt a self-positioning fixing method to achieve accurate positioning. This new roll-pressing and stamping forming process provides a valuable reference for the industrial application of batch-produced metal foils.

Key words

metal foil / compound forming / protrusion height / coincidence degree / groove

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LI Ting, WEI Xiaoji, SHI Yongjie, XIAO Zhuo, ZHANG Chunmiao. New Compound Forming Process of Roll-pressing and Stamping for Metal Foils with High Aspect Ratio Grooves[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 233-240 https://doi.org/10.3969/j.issn.1674-6457.2025.09.023

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