Multi-stage Micro Deep Drawing Process and Die Design of Pure Ti Foil Micro Cup Assisted by Forming Limit

HAN Peisheng; YANG Jixin; YANG Fengyuan; CHENG Zixing; CHI Hanghang; WANG Xiaogang

doi:10.3969/j.issn.1674-6457.2025.10.002

PDF(12066 KB)

Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (10) : 21-30. DOI: 10.3969/j.issn.1674-6457.2025.10.002

Light Alloy Forming

Multi-stage Micro Deep Drawing Process and Die Design of Pure Ti Foil Micro Cup Assisted by Forming Limit

HAN Peisheng^1,2,*, YANG Jixin¹, YANG Fengyuan¹, CHENG Zixing^1,2, CHI Hanghang¹, WANG Xiaogang^1,2

Author information +

History +

Abstract

To economically and effectively produce metal foil micro cup parts with a large height-to-diameter ratio, the work aims to monitor the strain state during multi-stage forming with the forming limit diagram and determine the number of forming stages and the drawing ratio for each stage. Firstly, the forming limit of 50 μm thick annealed TA1 pure titanium foils was determined through the digital image correlation and the Holmberg uniaxial tensile test. Then, the forming process and die for a target micro cup-shaped deep-drawn part (0.6 mm in diameter and 1.12 mm in height) were designed based on the forming limit diagram and numerical simulation. Finally, multi-stage micro deep drawing tests were conducted. The deformation behavior and formability of the material at each stage were analyzed to assess the feasibility of the forming process. Through simulations of micro-deep-drawing processes with punch diameters of 1 mm, 0.8 mm, and 0.6 mm, it was found that as the number of drawing stages increased, the strain at each position of the micro-cup gradually approaches the fracture zone from the safe zone in the forming limit diagram. By the third stage, the material reached its forming limit without the risk of failure. Although thinning occurred at the base fillet of the micro cup and near the rim of the sidewall, the final formed micro cup exhibited thinning of 18% and 21% at these two positions, respectively, while maintaining a relatively uniform thickness distribution. Through multi-stage micro deep drawing with drawing ratios of 1.6, 1.25, and 1.33, target micro cups are successfully produced, exhibiting no surface defects and a relatively uniform thickness distribution. Studies indicate that integrating forming limits with numerical simulations can effectively guide processes and die design.

Key words

TA1 pure Ti foils / multi-stage micro deep drawing / forming limit / numerical simulation / process and die design

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

HAN Peisheng, YANG Jixin, YANG Fengyuan, CHENG Zixing, CHI Hanghang, WANG Xiaogang. Multi-stage Micro Deep Drawing Process and Die Design of Pure Ti Foil Micro Cup Assisted by Forming Limit[J]. Journal of Netshape Forming Engineering. 2025, 17(10): 21-30 https://doi.org/10.3969/j.issn.1674-6457.2025.10.002

References

[1] 龚峰, 张顺, 吴挺岛. 1060纯铝微杯形件微拉深成形研究[J]. 机械工程学报, 2014, 50(24): 44-49.
GONG F, ZHANG S, WU T D.Research on Micro Deep Drawing of Pure Aluminum 1060 Micro Cylindrical Cups[J]. Journal of Mechanical Engineering, 2014, 50(24): 44-49.
[2] XU J, WANG X W, WANG C J, et al.A Review on Micro/Nanoforming to Fabricate 3D Metallic Structures[J]. Advanced Materials, 2021, 33(6): 2000893.
[3] 单德彬, 李虎山, 陈俞希, 等. 复杂微型构件特种能场辅助微成形研究进展[J]. 精密成形工程, 2024, 16(7): 23-47.
SHAN D B, LI H S, CHEN Y X, et al.Research Progress on Energy Field Assisted Micro-Forming of Complex Micro Parts[J]. Journal of Netshape Forming Engineering, 2024, 16(7): 23-47.
[4] HAN P S, YANG J X, CHENG Z X, et al.Study on Size Effect Affected Multi-Stage Micro Deep Drawing Forming Directly Using Pure Titanium Foils[J]. Materials Today Communications, 2025, 42: 111214.
[5] 关景锐. 薄壁不锈钢杯形件拉深成形质量控制研究[D]. 广州: 华南理工大学, 2015: 2-4.
GUAN J R.Study on Quality Control of Deep Drawing of Thin-walled Stainless Steel Cup-shaped Parts[D]. Guangzhou: South China University of Technology, 2015: 2-4.
[6] SUNDAR S S S P, RAJENDRAN R, HARSHAVARDHANA N. An Investigation of Hybrid Models FEA Coupled with AHP-ELECTRE, RSM-GA, and ANN-GA into the Process Parameter Optimization of High-Quality Deep-Drawn Cylindrical Copper Cups[J]. Mechanics Based Design of Structures and Machines, 2024, 52(1): 498-522.
[7] ARINBJARNAR Ú, SCHUMANN P, MOSKE J, et al.A Review of Methods and Effects for Improving Production Robustness in Industrial Micro-Deep Drawing[J]. International Journal of Material Forming, 2024, 17(3): 31.
[8] ZHAO J W, JIANG Z Y, WANG Z H, et al.An Analysis of Micro Deep Drawing of Ferritic Stainless Steel 430 Using Crystal Plasticity Finite Element Method[J]. Journal of Materials Research and Technology, 2022, 20: 2247-2261.
[9] IRTHIEA I, MAHMOOD Z.Effect of Process Parameters on Micro Flexible Deep Drawing of Stainless Steel 304 Cups Utilizing Floating Ring: Simulation and Experiments[J]. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2021, 235(1/2): 134-143.
[10] KALUJNIY O V, KALUJNIY V L, ALIIEV I S, et al.Investigation of Variants of Deep Drawing of Steel Hollow Parts[J]. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2024, 47(1): 19.
[11] WANG H Y, CHEN G, ZHANG P, et al.An Extended Mesoscaled M-K Model for Predicting Discrete Ultimate Strains and Evaluating the Effect of Normal Stress on Forming Limits[J]. Journal of Materials Processing Technology, 2024, 334: 118609.
[12] VINI M H, DANESHMAND S.Forming Limit Diagram and Plane Stress Fracture Toughness of Foil AA1050/TiC Composites[J]. International Journal of Material Forming, 2023, 16(4): 43.
[13] ELIZALDE S, COYOY P, CASAS C, et al.Study of the Effect of the Process Parameters on the Forming Limit in Shear Spinning Processes[J]. The International Journal of Advanced Manufacturing Technology, 2025, 136(7): 3303-3314.
[14] CHAN L C, FU M W, LI N, et al.FEA-Aided Design of Multi-Stage Drawing Process and Tooling for Production of a Miniature Sheet Metal Component[J]. The International Journal of Advanced Manufacturing Technology, 2010, 46(9): 993-1000.
[15] YEH F H, LI C L, TSAY K N. An Analysis of Forming Limit in Micro Deep Drawing of the Square Cup for Anisotropic Foil[J]. Applied Mechanics and Materials, 2011, 105/106/107: 344-347.
[16] 王维. 基于韧性破裂准则的金属板材渐进成形破裂预测[D]. 重庆: 重庆大学, 2017: 7-43.
WANG W.Fracture Prediction in Incremental Sheet Forming Based on Ductile Fracture Criterion[D]. Chongqing: Chongqing University, 2017: 7-43.
[17] 王国涛. 基于数值模拟的铁素体不锈钢换热板片成形过程研究[D]. 烟台: 烟台大学, 2024: 19-104.
WANG G T.Study on the Forming Process of Ferritic Stainless Steel Heat Exchanger Plates Based on Numerical Simulation[D]. Yantai: Yantai University, 2024: 19-104.
[18] 国家质量监督检验检疫总局, 中国国家标准化管理委员会. 钛及钛合金牌号和化学成分: GB/T 3620.1— 2016[S]. 北京: 中国标准出版社, 2016.
General Administration of Quality Supervision, Inspection and Quarantine of the People’s Republic of China, Standardization Administration of the People’s Republic of China. Designation and Composition of Titanium and Titanium Alloys: GB/T 3620.1—2016[S]. Beijing: Standards Press of China, 2016.
[19] HAN P S, YUAN G F, ZHU X Y, et al.Grain Size Effect of Pure Ti Foils by Micro Blanking-Deep-Drawing Compound Process[J]. The International Journal of Advanced Manufacturing Technology, 2022, 123(5): 1799-1810.
[20] QI Y Y, MA X G, MA L N, et al.Effects of Annealing Temperature on Micro Deep Drawing of Stainless Steel- Copper Composite[J]. IOP Conference Series: Materials Science and Engineering, 2022, 1270(1): 012092.
[21] HOLMBERG S, ENQUIST B, THILDERKVIST P.Evaluation of Sheet Metal Formability by Tensile Tests[J]. Journal of Materials Processing Technology, 2004, 145(1): 72-83.
[22] Metallic Materials-Determination of Forming-limit Curves for Sheet andStrip-Part 2: Determination of Forming-limit Curves in the Laboratory: ISO 12004—2: 2021[S]. International Organization for Standardization, 2021.
[23] PENG L F, XU Z T, FU M W, et al.Forming Limit of Sheet Metals in Meso-Scale Plastic Forming by Using Different Failure Criteria[J]. International Journal of Mechanical Sciences, 2017, 120: 190-203.
[24] 张秀平. 不锈钢深冲件表面桔皮现象的研究及改进[D]. 上海: 上海交通大学, 2017.
ZHANG X P.Study and Improvement on Orange Peel of Stainless Deep Drawn Parts[D]. Shanghai: Shanghai Jiao Tong University, 2017.
[25] HAN P S, XING Y L, YUAN G F, et al.Experimental Investigation of the Multi-Stage Micro-Deep Drawing of Pure Titanium Foils with Different Grain Sizes[J]. Journal of Materials Science, 2022, 57(31): 15094-15108.
[26] TANG X F, PENG L F, SHI S Q, et al.Influence of Crystal Structure on Size Dependent Deformation Behavior and Strain Heterogeneity in Micro-Scale Deformation[J]. International Journal of Plasticity, 2019, 118: 147-172.
[27] LUO L, JIANG Z Y, WEI D B, et al.An Experimental and Numerical Study of Micro Deep Drawing of SUS304 Circular Cups[J]. Manufacturing Review, 2015, 2: 27.
[28] ZHAO J W, ZHANG K X, MA X G, et al.Study on the Formability of Copper Foils during Multi-Step Micro Deep Drawing[J]. Journal of Materials Research and Technology, 2024, 28: 2187-2198.
[29] 李玲. SUS304不锈钢箔微拉深成形性能研究[D]. 太原: 太原理工大学, 2023: 47-56.
LI L.Study on the Formability of SUS304 Stainless Steel Foils in Micro Deep Drawing[D]. Taiyuan: Taiyuan University of Technology, 2023: 47-56.
[30] ZHAO H, MA X G, WANG Z H, et al.Surface Roughness Evolution and Heterogeneous Plastic Deformation of Austenitic Stainless Steel during Micro Deep Drawing: Modeling and Experiment[J]. International Journal of Plasticity, 2024, 176: 103964.
[31] 中国机械工程学会塑性工程学会. 锻压手册-第2卷-冲压[M]. 北京: 机械工业出版社, 2014: 304-306.
CMES. Forging Manual-Volume 2-Stamping[M]. Beijing: China Machine Press, 2014: 304-306.

Funding

The National Natural Science Foundation of China (52275358); Taiyuan University of Science and Technology Scientific Research Initial Funding (20232106, 20242076); Scientific and Technological Innovation Programs of Higher Education Institutions in Shanxi (2024L247)