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<p>Due to the size effect, the plastic deformation behavior in micro-forming is difficult to predict. In order to understand how the size effect affects the high temperature gas pressure micro-bulging process, this study used electrodeposited nanocrystalline copper foil as raw material, explored the high-temperature gas pressure micro-bulging process, observed the forming quality of micro-bulging hemispherical parts under different micro-bulging process parameters, and reconstructed the overall structure of micro-bulging parts by three-dimensional computer tomography technology. The forming mechanism of micro-bulging parts under complex stress state was revealed. On this basis, the surface layer model was used to study how the difference in deformation mechanism between surface grains and internal grains dominates the nonlinear change in the micro-forming process, and the formation mechanism of size effect was clarified. The results show that when the die diameter is 340&#xa0;μm, the bulging temperature is 600&#xa0;°C, and the foil thickness is 30&#xa0;μm, a micro-bulging part with a depth-diameter ratio of 0.371 and a maximum thinning rate of 20.8 % is obtained. The change of foil thickness shows that the thinner the foil thickness is, the larger the depth-diameter ratio is. At 550&#xa0;°C, the larger the die diameter, the larger the depth-diameter ratio. At 600&#xa0;°C, the larger the die diameter, the smaller the depth-to-diameter ratio, which is caused by the size effect in the micro-plastic forming process.</p> Graphical Abstract <p></p>

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Research on the Mechanism of Micro-Forming Size Effect Based on Three-Dimensional Reconstruction

  • 期刊论文

  • 发表日期：

    2025年10月29日

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  • You Li,
  • Yanan Ji,
  • Weiming Chen,
  • Hengjian Huang,
  • Hongbo Cui,
  • Yuchun Ji

摘要

Due to the size effect, the plastic deformation behavior in micro-forming is difficult to predict. In order to understand how the size effect affects the high temperature gas pressure micro-bulging process, this study used electrodeposited nanocrystalline copper foil as raw material, explored the high-temperature gas pressure micro-bulging process, observed the forming quality of micro-bulging hemispherical parts under different micro-bulging process parameters, and reconstructed the overall structure of micro-bulging parts by three-dimensional computer tomography technology. The forming mechanism of micro-bulging parts under complex stress state was revealed. On this basis, the surface layer model was used to study how the difference in deformation mechanism between surface grains and internal grains dominates the nonlinear change in the micro-forming process, and the formation mechanism of size effect was clarified. The results show that when the die diameter is 340 μm, the bulging temperature is 600 °C, and the foil thickness is 30 μm, a micro-bulging part with a depth-diameter ratio of 0.371 and a maximum thinning rate of 20.8 % is obtained. The change of foil thickness shows that the thinner the foil thickness is, the larger the depth-diameter ratio is. At 550 °C, the larger the die diameter, the larger the depth-diameter ratio. At 600 °C, the larger the die diameter, the smaller the depth-to-diameter ratio, which is caused by the size effect in the micro-plastic forming process.

Graphical Abstract