Grain size and workpiece dimension effects on material flow in an open-die micro-forging/extrusion process

• Published in: Materials science & engineering. A, Structural materials : properties, microstructure and processing Structural materials : properties, microstructure and processing, 2013-10, Vol.582 (10), p.379-388
• Main Authors: Ghassemali, Ehsan, Tan, Ming-Jen, Wah, Chua Beng, Jarfors, Anders E.W., Lim, S.C.V.
• Format: Article
• Language: English
• Subjects: Applied sciences; Condensed matter: structure, mechanical and thermal properties; Dead metal zone; Defects and impurities in crystals; microstructure; Dislocation cells; Exact sciences and technology; Forming; Heat treatment; Linear defects: dislocations, disclinations; Mechanical properties and methods of testing. Rheology. Fracture mechanics. Tribology; Metals. Metallurgy; Microforming; Physics; Production techniques; Size effect; Structure of solids and liquids; crystallography; Subgrain; Thermomechanical treatment
• ISSN: 0921-5093; 1873-4936; 1873-4936
• DOI: 10.1016/j.msea.2013.06.023

The interactive effect of grain size and specimen dimensions on the material flow and microstructural evolution was studied in a progressive open-die microforming process. Particular interest was paid on the effect of the number of grains over the initial specimen thickness, on the evolution of the dead metal zone (DMZ) in the final micro-component's microstructure. Such a DMZ is deemed unfavorable for mechanical properties of the pin. Interestingly, experimental results revealed that the DMZ can be removed at the pin surface by increasing the initial grain size. This behavior was attributed to the role of the strain gradient on the deformation. In the aspects of the forming load and dimensional measurements of the final parts, there were no significant size-effects observed in this process. This is because the neutral plane, which demarcates the two directions of material flow in the open-die forging/extrusion process, determines the amount of material flow towards the die orifice, regardless of the initial grain size.