Title: Understanding of plasticity size-effect governed mechanical response and incomplete die filling in a microscale double-punch molding configuration

Journal Article · · International Journal of Mechanical Sciences
 [1];  [2];  [3];  [4];  [4];  [4]
  1. Louisiana State Univ., Baton Rouge, LA (United States); OSTI
  2. Auburn Univ., AL (United States). National Center for Additive Manufacturing Excellence (NCAME); Louisiana State Univ., Baton Rouge, LA (United States)
  3. Auburn Univ., AL (United States). National Center for Additive Manufacturing Excellence (NCAME)
  4. Louisiana State Univ., Baton Rouge, LA (United States)
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Direct replication of microscale patterns onto metal surfaces by compression molding with patterned dies is used to fabricate metal-based structures for microsystem applications. Micron scale plasticity governs both the mechanical molding response and the geometric fidelity of replicated patterns. Microscale molding replication offers a technologically relevant example in which various plasticity size effects manifest themselves and control the effectiveness of the fabrication process. Furthermore, microscale compression molding of a single-crystal Al specimen was studied by combining experimentation with conventional and strain gradient plasticity finite element simulations. In the single-punch molding configuration, single rectangular punches with different widths and lengths were used. In the double-punch configuration, two identically-dimensioned rectangular punches with a spacing in between were used. Under single-punch molding at the micron scale, both the absolute punch width as well as the length-to-width ratio affected the characteristic molding pressure. Under double-punch molding, both the measured characteristic molding pressure and the material flow to fill the gap between the two rectangular punches exhibited a significant dependence on the spacing to punch-width ratio and—when this ratio was fixed—on the absolute spacing between punches. The present study elucidates the impact of plasticity size effects on the efficacy of pattern replication by molding at the micron scale.

Research Organization:
Louisiana State Univ., Baton Rouge, LA (United States)
Sponsoring Organization:
National Institutes of Health (NIH); National Science Foundation (NSF); USDOE Office of Science (SC)
Grant/Contract Number:
SC0019378
OSTI ID:
1803736
Journal Information:
International Journal of Mechanical Sciences, Journal Name: International Journal of Mechanical Sciences Journal Issue: C Vol. 172; ISSN 0020-7403
Publisher:
ElsevierCopyright Statement
Country of Publication:
United States
Language:
English

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42 ENGINEERING
97 MATHEMATICS AND COMPUTING
incomplete die filling
mechanical size effects
micro molding
pattern replication
plasticity
strain gradient