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Micromachines 2017, 8(5), 142; doi:10.3390/mi8050142

Ultrasonic-Assisted Incremental Microforming of Thin Shell Pyramids of Metallic Foil

Institute of Industrial Science, The University of Tokyo, Tokyo 153-8505, Japan
Current address: Center for Manufacturing Science and Technology, Tokyo Denki University, Tokyo 120-8551, Japan.
Current address: Nidec Center for Industrial Science, Nidec Corporation, Kawasaki 212-0032, Japan.
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Author to whom correspondence should be addressed.
Academic Editor: Guido Tosello
Received: 28 February 2017 / Revised: 11 April 2017 / Accepted: 25 April 2017 / Published: 3 May 2017
(This article belongs to the Special Issue Micro/Nano Manufacturing)
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Abstract

Single point incremental forming is used for rapid prototyping of sheet metal parts. This forming technology was applied to the fabrication of thin shell micropyramids of aluminum, stainless steel, and titanium foils. A single point tool used had a tip radius of 0.1 mm or 0.01 mm. An ultrasonic spindle with axial vibration was implemented for improving the shape accuracy of micropyramids formed on 5–12 micrometers-thick aluminum, stainless steel, and titanium foils. The formability was also investigated by comparing the forming limits of micropyramids of aluminum foil formed with and without ultrasonic vibration. The shapes of pyramids incrementally formed were truncated pyramids, twisted pyramids, stepwise pyramids, and star pyramids about 1 mm in size. A much smaller truncated pyramid was formed only for titanium foil for qualitative investigation of the size reduction on forming accuracy. It was found that the ultrasonic vibration improved the shape accuracy of the formed pyramids. In addition, laser heating increased the forming limit of aluminum foil and it is more effective when both the ultrasonic vibration and laser heating are applied. View Full-Text
Keywords: incremental microforming; ultrasonic spindle; shin shell micropyramid; metallic foil; forming limit; shape accuracy incremental microforming; ultrasonic spindle; shin shell micropyramid; metallic foil; forming limit; shape accuracy
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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Obikawa, T.; Hayashi, M. Ultrasonic-Assisted Incremental Microforming of Thin Shell Pyramids of Metallic Foil. Micromachines 2017, 8, 142.

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