Plastic anisotropy of ultra-thin rolled phosphor bronze foils and its thickness strain evolution in micro-deep drawing

T Shimizu, M Ogawa, M Yang, K Manabe - Materials & Design (1980-2015), 2014 - Elsevier
T Shimizu, M Ogawa, M Yang, K Manabe
Materials & Design (1980-2015), 2014Elsevier
Metal foils are highly advantageous for producing microcomponents with high-aspect-ratio
three-dimensional shapes by miniaturizing the process dimensions in sheet-metal-forming
technologies. To characterize existing rolled metal foils at manufacturing sites and to clarify
the impact of its strong anisotropic properties on micro-sheet formability, tensile tests and
micro-deep drawing tests were performed on phosphor bronze foils with thicknesses of 20–
300 μm. Focusing on the Lankford value (r-value) as a useful parameter for conventional …
Abstract
Metal foils are highly advantageous for producing microcomponents with high-aspect-ratio three-dimensional shapes by miniaturizing the process dimensions in sheet-metal-forming technologies. To characterize existing rolled metal foils at manufacturing sites and to clarify the impact of its strong anisotropic properties on micro-sheet formability, tensile tests and micro-deep drawing tests were performed on phosphor bronze foils with thicknesses of 20–300 μm. Focusing on the Lankford value (r-value) as a useful parameter for conventional sheet-metal-formability, the relation between the r-value of ultra-thin rolled foil and its applicability in micro-deep drawing is investigated. Ultra-thin rolled foil is characterized with a higher r-value due to the strong texture of {1 1 0} and {1 1 1} textures. Although the in-plane tendency of the r-value showed a strong correlation with the thickness distribution of micro-drawn cups, the obtained higher r-value for thinner foils does not correspond to the lower formability of thinner metal foils. As relevant parameter for indicating the forming limit for thin-rolled metal foils, the nonuniformity in thickness due to surface roughening is introduced. The importance of a geometrical anisotropy, such as orientation of surface topography and defects, for the unstable deformation of ultra-thin rolled metal foils is experimentally demonstrated.
Elsevier
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