From single to multi-stage forming process of copper thin sheet
In the electronics industry sector, different types of parts made out of copper alloys are used, such as metal supports (lead frames), on which the chips are assembled. These parts are produced using progressive dies, with several blanking and bending stages. There is a huge interest to numerically...
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EDP Sciences
2025-01-01
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| Series: | Mechanics & Industry |
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| Online Access: | https://www.mechanics-industry.org/articles/meca/full_html/2025/01/mi240071/mi240071.html |
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| author | Lagroum Amine Manach Pierre-Yves Thuillier Sandrine |
| author_facet | Lagroum Amine Manach Pierre-Yves Thuillier Sandrine |
| author_sort | Lagroum Amine |
| collection | DOAJ |
| description | In the electronics industry sector, different types of parts made out of copper alloys are used, such as metal supports (lead frames), on which the chips are assembled. These parts are produced using progressive dies, with several blanking and bending stages. There is a huge interest to numerically predict these multistage forming processes, to decrease design time and to anticipate production problems such as non-compliance with dimensional tolerances depending on the material used. This paper deals with the progressive forming of copper parts with single and multi-stage process coupled with experimental and numerical approaches for bending operations. The main contribution of this study is the design of a single stage bending tool for rectangular samples representative of multi-stage industrial processes, providing a relevant experimental database for numerical model validation. This device is based on the technology of progressive dies, though it allows the production of one part at a time. Instrumentation provides local load and displacement and an experimental database is built for Cu-ETP R290 copper strip. A multi-stage bending industrial process dedicated to the manufacturing of electrical contacts is also considered in this study. Numerical models of both single and multi-stage processes are developed, with a focus on the technological importance of a cam slider for the industrial process. The results show that the bending force is mainly influenced by the sample width. In addition, numerical models for the rectangular geometries capture some of the trends from the experiment such as the proportionality of the maximum force with the bent width. Overall, the models are able to predict springback within the process tolerance. Finally, comparison of one stage of the bending sequence with the single stage bending model showed that the single model approach gives similar results in terms of load and plastic deformation. |
| format | Article |
| id | doaj-art-d97eff41d7694627978c75675ed7904b |
| institution | Kabale University |
| issn | 2257-7777 2257-7750 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | EDP Sciences |
| record_format | Article |
| series | Mechanics & Industry |
| spelling | doaj-art-d97eff41d7694627978c75675ed7904b2025-02-07T08:25:52ZengEDP SciencesMechanics & Industry2257-77772257-77502025-01-0126410.1051/meca/2024039mi240071From single to multi-stage forming process of copper thin sheetLagroum Amine0https://orcid.org/0000-0001-6612-7694Manach Pierre-Yves1https://orcid.org/0000-0002-7810-3486Thuillier Sandrine2https://orcid.org/0000-0003-1259-2456Univ. Bretagne Sud, UMR CNRS 6027, IRDLUniv. Bretagne Sud, UMR CNRS 6027, IRDLUniv. Bretagne Sud, UMR CNRS 6027, IRDLIn the electronics industry sector, different types of parts made out of copper alloys are used, such as metal supports (lead frames), on which the chips are assembled. These parts are produced using progressive dies, with several blanking and bending stages. There is a huge interest to numerically predict these multistage forming processes, to decrease design time and to anticipate production problems such as non-compliance with dimensional tolerances depending on the material used. This paper deals with the progressive forming of copper parts with single and multi-stage process coupled with experimental and numerical approaches for bending operations. The main contribution of this study is the design of a single stage bending tool for rectangular samples representative of multi-stage industrial processes, providing a relevant experimental database for numerical model validation. This device is based on the technology of progressive dies, though it allows the production of one part at a time. Instrumentation provides local load and displacement and an experimental database is built for Cu-ETP R290 copper strip. A multi-stage bending industrial process dedicated to the manufacturing of electrical contacts is also considered in this study. Numerical models of both single and multi-stage processes are developed, with a focus on the technological importance of a cam slider for the industrial process. The results show that the bending force is mainly influenced by the sample width. In addition, numerical models for the rectangular geometries capture some of the trends from the experiment such as the proportionality of the maximum force with the bent width. Overall, the models are able to predict springback within the process tolerance. Finally, comparison of one stage of the bending sequence with the single stage bending model showed that the single model approach gives similar results in terms of load and plastic deformation.https://www.mechanics-industry.org/articles/meca/full_html/2025/01/mi240071/mi240071.htmlcopper sheetbendingprogressive diesexperimentfinite element |
| spellingShingle | Lagroum Amine Manach Pierre-Yves Thuillier Sandrine From single to multi-stage forming process of copper thin sheet Mechanics & Industry copper sheet bending progressive dies experiment finite element |
| title | From single to multi-stage forming process of copper thin sheet |
| title_full | From single to multi-stage forming process of copper thin sheet |
| title_fullStr | From single to multi-stage forming process of copper thin sheet |
| title_full_unstemmed | From single to multi-stage forming process of copper thin sheet |
| title_short | From single to multi-stage forming process of copper thin sheet |
| title_sort | from single to multi stage forming process of copper thin sheet |
| topic | copper sheet bending progressive dies experiment finite element |
| url | https://www.mechanics-industry.org/articles/meca/full_html/2025/01/mi240071/mi240071.html |
| work_keys_str_mv | AT lagroumamine fromsingletomultistageformingprocessofcopperthinsheet AT manachpierreyves fromsingletomultistageformingprocessofcopperthinsheet AT thuilliersandrine fromsingletomultistageformingprocessofcopperthinsheet |