Understanding Size Effects and Forming Limits in the Micro-Stamping of Industrial Stainless Steel Foils

Weiß, Matthias; Zhang, Peng; Pereira, Michael; Rolfe, Bernard; Wilkosz, Daniel E.; Hodgson, Peter

doi:10.3390/met11010038

Cited by 9 publications

(3 citation statements)

References 49 publications

(61 reference statements)

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“…For this, however, other manufacturing processes and particle shapes would have to be investigated with regard to manufacturing tolerances and damage behavior. It would be conceivable to produce the test particles by micro-embossing [ 23 , 24 , 25 ] and then to harden the ductile materials [ 26 , 27 ] in order to obtain the required strength. Again, abstract shapes would be feasible, which so far is the only approach for DEM-CFD simulation.…”

Section: Discussionmentioning

confidence: 99%

Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs

Brag,

Piotter,

Plewa

et al. 2023

Materials

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In subtractive manufacturing processes, swarf, burrs or other residues are produced, which can impair the function of a tribological system (e.g., journal bearings). To prevent premature engine damage, cleanliness requirements are defined for production processes. Damaging particle tests are an experimental approach for validating these defined cleanliness requirements. This methodical approach is not yet widely used. For one, the test setup must be developed and proven for the respective application. For another, in order to carry out the tests in a systematic manner, defined test particles with properties similar to those of the contaminants encountered in reality are required. In the second part of the paper, the process chain for manufacturing artificial test swarf by micro powder injection molding (MicroPIM) is described. The size and shape of the swarf were derived from real swarf via several abstraction processes. Although certain design guidelines for MicroPIM parts could not be taken into account, the targeted manufacturing tolerances were achieved in most cases. During demolding, it became apparent that the higher ejection forces of the free-formed geometries must be taken more into account in the design of the mold. The experiments on the test setup also revealed that the artificial test swarf was unexpectedly brittle and was therefore ground up in the bearing gap without causing any substantial damage to the bearing. Thus, the artificial test swarf in its current sintered state is not a suitable substitute for micromilled swarf. However, MicroPIM could still be used to manufacture test particles in applications involving lower mechanical forces.

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Section: Discussionmentioning

confidence: 99%

Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs

Brag,

Piotter,

Plewa

et al. 2023

Materials

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“…Foil printing methods, in terms of efficiency and efficacy, are currently dominated by UV flexographic and UV lithographic offset printing technologies, the main reason being that they cause prints to dry quickly. Polymer printing involving the controlled production of small printing elements has a great influence on the size and forming limits of printed items in later micro-stamping procedures [3,4].…”

Section: Introductionmentioning

confidence: 99%

The Effect of Applying UV LED-Cured Varnish to Metalized Printing Elements during Cold Foil Lamination

Majnarić,

Morić,

Valdec

et al. 2024

Coatings

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The coating process involves applying a thin material layer to a surface to engender it with specific desirable properties or enhance its performance. In the production of print media (labels, packaging, printed textiles, and promotional materials), the standard functions of the coating process include visual decoration, which involves the addition of appealing colors, textures, and patterns. A pertinent issue in the printing industry is that at present, the predominant coating process uses printing and coating technologies (gravure, flexo, letterset, letterpress, screen printing, inkjet, and electrophotography) and lamination (i.e., attaching decorative layers of materials, such as films or fabrics). In this paper, we present a new method for testing the efficiency with which different-sized metalized printing elements (using gold foil) may be applied to paper substrates; to do so, we gradually vary the amount UV-cured inkjet varnish (or adhesive) that is applied. To test the effectiveness of this method in producing metallic visual effects, we utilize seven different thicknesses of UV-cured varnish with the aid of modular piezo inkjet heads (KM1024 iLHE-30) and three different printing speeds. Our research shows that to achieve optimal production of cold metalized foil, a 21 µm layer should be deposited, and the substrate should move at a speed of 0.30 m/s.

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“…Bipolar plates can be made of various materials, and metal bipolar plates have been considered to reduce weight and enable high-volume manufacture at low cost [3]. Aluminium alloys [4], titanium [5], and stainless steel [6] have been applied for metal bipolar plates and formed with stamping [7], rubber pad forming [8], and hydroforming [9]. Liu and Hua [10] applied rubber pad forming to manufacture multi-row micro-channels from SS304.…”

Section: Introductionmentioning

confidence: 99%

Finite element model for micro-stamping titanium bipolar plate

KHADEMI

2023

Materials Research Proceedings

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Abstract. Bipolar plates are the essential components of a Proton Exchange Membrane Fuel Cell. Lightweight bipolar plates can be micro-stamped from an ultrathin metallic foil. A major concern is the manufacturability of the foil in the micro-stamping process. The typical stamped micro-channels have end cavities or corners where the deformation mode can be different from the two-dimensional plane strain conditions that occur at the straight sections of the micro-channels. The thin foil has a large ratio of length (or width) to thickness, and shell elements were often used for three-dimensional models. Currently, it is unknown if the shell elements available in commercial software packages are able to predict the ultrathin material behaviour correctly. In addition, the deformation behaviour and forming limits of titanium foil in the micro-stamping process are not well understood. The current study uses a micro-stamping tool to produce straight micro-channels from commercially pure titanium foil. The experimental data are used to validate a two-dimensional and a three-dimensional finite element model of the process. It is shown that there are deviations between the experimental and the numerical thinning results. Material thinning is different between the straight and the cavity end sections suggesting that three-dimensional process models are required to accurately analyze forming.

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Understanding Size Effects and Forming Limits in the Micro-Stamping of Industrial Stainless Steel Foils

Cited by 9 publications

References 49 publications

Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs

Development and Production of Artificial Test Swarf to Examine Wear Behavior of Running Engine Components—Part 2: Experimentally Derived Designs

The Effect of Applying UV LED-Cured Varnish to Metalized Printing Elements during Cold Foil Lamination

Finite element model for micro-stamping titanium bipolar plate

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