Structural Analysis of a Micro-Former Based on Results from the Forming Analysis of Milli-Component

Abstract

Manufacturing process for milli-components has recently gained researcher’s focus with the increasing tendency toward highly integrated and micro-scaled parts for electronic devices. This process, however, requires high production cost and more accurate final shapes than the conservative forming process technique. In order to fulfill this requirements, the numerical analysis must be preceded in design of the dies and dimensions for components. This paper is concerned with the forming analysis and the structural analysis of milli-components. Forming analysis of milli-components has been studied with a new micro-former with progressive dies. Multi-stage forming sequence has been analyzed with finite element method by LS-DYNA3D. The analysis considers the effect of elastic dies on the dimensional accuracy of the formed parts in order to enhance the forming accuracy and productivity. The analysis result demonstrates that the elastic analysis in the milli-forming process is indispensable for accurate forming analysis. And then, structural analysis for a micro-former has been carried out using the forming analysis results such as punch loads and die pressure. The result provides useful information in design of a new micro-former and milli-components.