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Deliverables
Philips produces a wide range of sheet metal products. The technical limitations of conventional (micro) metal forming processes (stamping) have been reached. Assisting processes, added to the conventional stamping process, can provide a way to exceed these process limits. An overview has been made of Philips metal micro parts described by characteristics, which define the technical limitations of (micro) metal forming processes with the specification of the achievable and the expected accuracies. The chosen demonstrators are trimmers, electron gun parts and actuator springs in particular in high alloyed steel materials.
Simulation approaches using different FE models were established in terms of grain- size effect, static and dynamic behaviour of tools and machines, the material behaviour of the work piece and theoretical enlargements of process limits. To get a more detailed basic knowledge of the investigated processes simulation models were developed for the assisted stamping processes such as the E-Stamping, laser assisted stamping and high speed stamping.
The E- Stamping technology is based on the heating of the cutting line by a resistance principle. A current flows through the strip material from the punch to the cutting die. Due to the current transfer resistance from the punch to the strip, within the strip and the current transfer to the cutting die a heat rises in the strip material. A special tool with appropriate insulations and a resistance welding machine as a current generator were designed and machined/ modified. A timer controls the duty cycle by switching the current. With E-Stamping assistance force reductions of more than 50% can be reached.
To qualify the current assisted stamping for mass production, a satisfying lifetime of the active tool parts is required. A scanning of tool materials shows a range of suitable materials, which can be used as a punch material for E- Stamping. E- Stamping tests with a temperature measurement with different tool materials show different results in the suitability of the materials. Therewith suitable materials could be defined.
For laser assisted heating different transparent tool materials were tested. From the economic and technical point of view sapphire is the best-suited material. The negative of the embossing microstructure is reproduced in the sapphire. In response to this application a laser ablation machine was set up and sapphire demonstrators were machined to provide active transparent tool parts for a laser assisted embossing and extruding process.
To enable a stamping and bending process without a lubricant, special materials for active tool parts are necessary. A scanning of different ceramic materials results in a small range of ceramics, which are suitable to be used as active tool parts for dry stamping. The advantage is the omission of lubricants for the processing of surface coated work pieces, which are produced under high- purity conditions. A technology for machining ceramic tool parts by eroding, grinding and polishing was developed and a tool for the holding of ceramic active tool parts was designed and tested. A dry metal processing was successful and is implemented in an industrial production line.
Demands on modern copper base materials are still growing. Better mechanical and electrical properties to fulfill the increasing functionality of electric and electronic components are one reason for a development and a modification of new copper alloys. The state of the art concerning copper alloys and dimensions for electronic and electric applications (connectors/ lead frames) was defined. To test new copper alloys a material with a microstructure precipitation (almost 1µm) was developed to test the influence of the grain size on the achievable quality of the stamped parts. For the simulation of the investigated processes necessary material data were not available. For some selected materials special tension tests at higher temperatures and higher strain rate were performed.
The laser assisted stamping is based on the heating of the cutting line by laser radiation. A laser beam optic is integrated in the upper part of the tool and is guided through a hollow in the punch directly onto the strip material. By heating the strip material the temperature increases and the cutting force decreases up to 35%. A process limit of the heating by laser radiation is given by the rise of annealing colours in the good part (strip materials).
The laser assisted embossing is based on the heating of the work piece by laser radiation. A laser beam optic is integrated in the upper part of the tool and is guided through a sapphire cylinder directly onto the work piece. The sapphire cylinder is used as an active embossing tool part, and is optional with the embossing structure inside. By heating the strip material the temperature of the work piece increases and due to the lower yield stress the moulding degree increases.
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