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Mold Size Effect in Microscale Laser Dynamic Flexible Bulging Assisted by Laser Pre-Shocking.
Yijun Fang1,2, Pin Li2,3, Xijin Zhen3
1School of Agricultural Engineering, Jiangsu University, Zhenjiang 212013, China.
Micromachines
|May 28, 2022
Summary
Mold size significantly impacts micro-formed part quality. Optimizing mold size in microscale laser dynamic flexible bulging (μLDFB) is crucial for better surface finish and forming uniformity, with laser pre-shocking further enhancing results.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Surface Engineering
Background:
- The size effect is a critical challenge in micro-forming, affecting the quality of micro-formed parts.
- Understanding mold size effects is essential for optimizing microscale laser dynamic flexible bulging (μLDFB) processes.
- Surface quality and forming uniformity are key indicators of successful micro-forming.
Purpose of the Study:
- To investigate the influence of mold characteristic size on the forming quality of copper foils in μLDFB.
- To analyze the relationship between laser pulse energy, plastic strain, and the failure stages of bulging samples.
- To evaluate the effectiveness of laser pre-shocking (LPS) in improving the forming quality and performance.
Main Methods:
- Experimental analysis of microscale laser dynamic flexible bulging (μLDFB) with varying mold characteristic sizes.
- Systematic variation of laser pulse energy to observe different deformation and fracture stages.
- Introduction and comparative testing of laser pre-shocking (LPS) technique.
Main Results:
- Optimal mold characteristic sizes exist for achieving superior forming quality; small sizes yield poor surface quality, while large sizes reduce symmetry and uniformity.
- Increased laser pulse energy leads to higher plastic strain and progresses through five distinct failure stages, including necking and fracture.
- Laser pre-shocking (LPS) demonstrably improves surface quality and forming performance, delaying local necking and increasing the forming limit.
Conclusions:
- Mold size is a critical parameter that must be carefully controlled in μLDFB to balance surface quality and forming uniformity.
- Laser pulse energy influences the failure mechanisms, with surface roughening and grain size playing a role in fracture initiation.
- Laser pre-shocking (LPS) is a viable method to enhance the micro-forming process, improving overall part quality and process limits.
