DTU Studieprojekt - Investigation of scale effects in micro forming

Danmarks Tekniske Universitet (DTU)

Investigation of scale effects in micro forming

Udbyder
Vejleder
Sted
København og omegn
Motivation
When the need for manufacturing metallic components in large quantities rises, cold forming is often the chosen method to realize the production. Cold forming combines high production capacities with advantageous mechanical properties of components and little material waste. Conventional cold forming is quite a mature field and has a lot of knowledge that has been accrued over many years. Recently, it has been applied to produce smaller and smaller components, sometimes a single millimetre in diameter from material that is thinner than a human hair. Some examples of micro formed components are shown in the pictures. Conventional cold forming knowledge can not be transferred to this micro-scale forming due to so-called scale effects.

This project involves the investigation of select scale effects that occur in cold micro bulk metal forming. Of interest are scale effects that are independent of workpiece grain size, i.e. the grain size of the workpiece will be scaled along with workpiece dimensions to ensure that the measured parameters are not affected by the grain size, as per the theory of similarity. The scale effect should become apparent if some parameter is held constant through the geometrical scaling of the workpiece. For example, if the surface roughness is held constant and the workpiece size is reduced it leads to an increase in friction during forming. This is a known scale effect that can already be accounted for by considering the ratio of open lubricant pockets to closed ones.

The project involves the usage of a custom-made piece of equipment known as a micro-tribotester that was built as part of an EU-project. There is not very much work that has been done on it so far, so there is room for discovery in the project.

Project objectives

Choose interesting parameters to investigate and predict what will occur when they are held constant through geometrical scaling. Such as: surface roughness and texture, material mechanical properties, lubricant formulation, drawing speed, etc.
Materials characterization to quantify grain size of different specimens, and whichever parameter is chosen to be investigated.
Experimental planning through design of experiments and experimental work on the micro-tribotester to identify scale effects.
Quantification of influence of each parameter that is investigated and cross-effects.

Feel free to be in contact for more information.

Supervisors:
Chris V. Nielsen (Associate Professor, cvni@mek.dtu.dk)
Úlfar Arinbjarnar (PhD Student, ulari@mek.dtu.dk)
Emneord

Konstruktion og mekanik
Elektroteknologi
Energi
Informationsteknologi
Materialer
Produktion og ledelse
Forbrændingsmotorer
Kyster og havne
Maskinkonstruktion
Skibe og off-shore-konstruktioner
Robotteknik og automation
Energiproduktion
Kraftværker
Entreprenørskab
Innovation og produktudvikling
Livscyklusanalyse
Operationsanalyse
Systemanalyse

Tags

designofexperiments
experimentalwork
experiments
Forming
Manufacturing
MaterialsCharacterization
materialtesting
mechanicaltesting
Metalforming
microforming
microscale
Scaledown
scaleeffects
sizeeffects
tribologicaltesting
tribology

Kontakt
Virksomhed/organisation
DTU Mekanik

Navn
Ulfar Arinbjarnar

Stilling
Ph.d.-studerende

Mail
ulari@mek.dtu.dk

Vejleder-info
Bachelor i Design & Innovation
Vejleder
Ulfar Arinbjarnar

Medvejledere
Chris Valentin Nielsen

ECTS-point
30