Micro metal parts are usually produced in large lot sizes at high production rates. In order to achieve sufficient product quality, excessive tool wear has to be avoided. Conventional methodologies for tool wear measurement usually require tools to be disassembled and measured separately. Since accuracy of handling and assembly is limited in micro range, a reproducible tool positioning between measurements cannot be guaranteed. Therefore, analysis of tool wear development is hardly possible using conventional methods. In this study, an inline tool wear measurement methodology is investigated. Instead of measuring the tool itself, it is based on the measurement of the forming product. Therefore, lateral upsetting experiments on 1.4301 stainless steel wires with a diameter of 0.3 mm are carried out on a micro forming press. The indentation geometry on the wire is measured optically and compared to the tool geometry. It is shown that both are in good agreement for different states of tool wear and that features with geometrical characteristics above 2 μm are transferred onto the indentation surface. Thus, the investigated methodology presents a feasible way for inline tool wear measurement.
Micro metal parts are usually produced in large lot sizes at high production rates. In order to achieve sufficient product quality, excessive tool wear has to be avoided. In the micro range, so-called scaling effects and their influence on tool wear in micro forming have not been investigated so far. For the investigation, tests in micro deep drawing were carried out with metal sheets (s < 50 μm) of pure aluminum Al99.5, a copper alloy E-Cu58 and stainless steel 1.4301. The failure mechanisms of the micro cups produced were identified as bottom fracture and cup wall damage, and tool wear was measured and characterized with optical measurements and EDX analyses. Moreover, micro cups can be produced by DLC-and PVD-coated tools in a dry forming process. To investigate the wear behavior in a continuous process, a forming tool was developed with an integrated blanking and deep drawing die. The tool wear was measured optically, and the wear mechanisms could be identified in a combined micro and deep drawing process. As a result, the tool could be modified by a manufacturing in selective laser melting and the tool life increased by 290%. Furthermore, a method for tool wear examination in long-term tests was developed. In lateral micro upsetting, the tool wear history can be examined by analyzing the formed product. Several tool materials and coatings were tested with up to 500,000 strokes.
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