Journal of Solid Mechanics
2, 2013
and Materials
Engineering
*Received 17 Sep., 2012 (No. 12-0373)
[DOI: 10.1299/jmmp.7.251]
Copyright 2013 by JSME
Vol. 7, No.
Scale Dependence of
Adhesion Behavior under Dry Friction
in Progressive Micro-Deep Drawing*
Tetsuhide SHIMIZU**, Yushiro MURASHIGE***, Syuhei IWAOKA****,
Ming YANG** and Ken-ichi MANABE*****
**Division of Human Mechatronics Systems, Tokyo Metropolitan University
6-6 Asahigaoka Hachiohjishi, 191-0065, Tokyo, Japan
E-mail: simizu-tetuhide@tmu.ac.jp
***Ditto, Presently, Murata Manufacturing Co., Ltd
****Ditto, Presently, Seiko Epson Corp.
*****Department of Mechanical Engineering, Tokyo Metropolitan University
1-1 Minamiohsawa, Hachiohjishi, 192-0397, Tokyo, Japan
Abstract
The present study aims to clarify the scale dependency of progressive adhesion
behavior of work material on micro tools under the dry friction in microforming.
Scaled progressive deep drawing test up to 300 times is conducted under dry
condition in micro- and milli- scale. The process dimensions of 0.97mm and
5.82mm in drawn cup diameter are produced with the stainless steel foils of
0.05mm and 0.3mm in thickness, respectively. The experimental results show that
the transition of maximum punch force has different tendencies in each scale. These
tendencies are well corresponded to the transition in surface state of tools and
drawn cups. While, the strong adhesive wear is observed for the milli-scale, there is
a slight change in the surface state of the tools for micro-scale. To investigate this
difference in the adhesion behavior of the work material in each scale, a finite
element analysis considering surface asperities is conducted. The distribution of the
adhesion volume on the die corner radius is evaluated with a semi-empirical wear
model in which is calculated with a function of normal pressure and relative
velocity between blank and die. The results show the low adhesion volume in
micro-scale, due to the short sliding distance during the process. The progressive
adhesion behavior of work material and the advantage of tool life in micro-scale
metal forming are demonstrated.
Key words: Microforming, Size Effect, Adhesion, Dry Friction, Micro-Deep
Drawing, Metal Foils
1. Introduction
Micro/nano manufacturing technology is gaining importance due to the trend towards
higher integrated functional density and miniaturization in electronics, consumer products,
energy generation and storage, medical devices and micro-electromechanical systems
(MEMS), which characterize today many products pushing forward their miniaturization.
As one of the most economical mass production methods for micro to sub-millimeter range
components, the miniaturization of conventional metal forming technology has been paid a
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great attention (1). Especially, metal foil has the great advantage to produce high-aspect
three-dimensional shapes by miniaturizing the process dimensions of sheet metal forming
technologies (2). However, due to the size effect, the process cannot directly be transferred to
the micro-scale (3).
One of the most important process factors in sheet metal forming is the interfacial
behavior between the tool and the material. Over the last decade, basic researches of the
size effect of tribology in microforming have been performed worldwide (4). The general
understanding for the friction size effect is the low effect of lubricant in micro-scale region
(5, 6)
. In addition, from the standpoint of dirt handling, contamination of the product, and
unstable formability, it is preferred not to use a lubricant for microforming process (7).
Under the dry friction condition, while the applied researches on dry forming with a
hard coating technology have been well progressed (7-10), basic research on the tribological
behavior of dry friction is not well discussed, especially for the micro-sheet metal forming
(11)
. Investigations of the scale dependence under dry sliding friction were reported by
Messner et al, (12) and Krishnan et al (13, 14). They reported the scale independency of the
friction coefficient. Author also has studied the friction behavior during the micro-deep
drawing process, focusing on the effect of surface asperities of dies and work pieces under
dry friction, and its scale dependency during the process (15, 16).
Although the basic researches of size effect of friction behavior have been investigated,
there are no reports related to the progressive transition behavior of tribological
characteristics, such as the wear of tools and the adhesion of work materials in
microforming. This is of great significance for the tool life and the reproducibility of the
micro-parts.
Within the above background, this study aims to clarify the progressive transition
behavior of tool wear and adhesion of work material under the dry friction condition in
microforming. In this report, scaled progressive dry micro deep drawing test up to 300
times in two different process dimensions, milli- and micro- scale, is presented. By using
stainless steel foils of 300m thick for milli-scale and 50m thick for micro scale, the
transition of the adhesion behavior of work material are evaluated. Additionally, to
evaluate the scale dependence of the wear volume quantitatively, finite element (FE)
analysis of scaled deep drawing is carried out.
2. Materials and Experimental Setup

2.1 Materials
The material used was a thin-rolled stainless steel foil (JIS: SUS304) of 300m nominal
thickness for milli-scale test and that of 50m nominal thickness for micro-scale. Table 1
shows the mechanical properties, obtained by a tensile test of the SUS304 foils for each
thickness. This tensile test was conducted according to the DIN 50125 H630 standard (17).
Compared with the 300m thick foil sample, the ultra-thin 50m thick foil sample
indicates the relative higher tensile strength of B: 1337MPa and considerably lower
elongation of f: 6%. These tendencies are well consistent with a report by Simons et al. (18),
which seems to be attributed to the work-hardening due to the higher working ratio of the
rolling process for thinner foils.
Fig.1 shows the initial surface quality of the foil in each scale, obtained by a confocal
laser scanning microscopy (LEXT OLS3000, Olympus Co.). The initial surfaces of the both
foils have rolling traces with the surface roughness of 0.11mRa for the 50m thick foil and
0.31mRa for the 300m thick foil. Since the difference in surface roughness between the
specimens is approximately 0.2mRa of arithmetic average surface roughness, the influence
of the initial surface roughness could be negligible.

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Table 1 Mechanical properties of SUS304 foils with different thickness

Initial thickness t0/m 300 50
Youngs modulus E /GPa 176 185
Yield stress y /MPa 721 1280
Tensile strength B /MPa 1168 1337
Elongation /% 37 6

TD TD

100m 100m
RD RD
(a)300m thick foil for milli-scale (b) 50m thick foil for micro-scale
Fig. 1 Initial surface images of the SUS304 specimens obtained by the cofocal laser
scanning microscopy (LEXT OLS3000, Olympus Co.)

2.2 Experimental setup

In this investigation, the process dimensions of deep drawing tool assembly for
milli-scale test were designed 6times larger than those for the micro-scale tooling set, based
on the scale difference of the thickness of the foil sample (300m/50m=6). In order to
describe the scaling parameter based on this foil thickness dimension, the length scale was
introduced through the whole present study. Here, the length scale was defined =1 for
milli-scale process dimension and =1/6 for the micro-scale dimension. Details of the tool
geometries in both scales are shown in Table 2. As shown in Table 2, tool set was designed
to produce the cups of 1.88 drawing ratio and 5.82mm diameter for milli- scale and 0.97mm
diameter for micro-scale. Both drawing dies in each scale were made of sintered WC-Co
hard alloy (JIS: V20 tungsten-carbide-cobalt alloy).
The erichsen cupping tester was used as the press machine for the milli-scale test.
Meanwhile for the micro-scale test, a miniature precision press machine of desktop size was
developed by Microfabrication Lab. Llt, as shown in Fig.3 (a). This press machine is
actuated by a servomotor and it is possible to supply materials progressively for the
continuous drawing test (20).
As for the micro-scale process, to facilitate the handling of the tiny pieces of blank
sample and to enhance the positioning accuracy of the central axis of the drawing process,
blanking process and drawing process are combined. Fig.3 (b) shows the appearance of the
palm sized blanking-drawing die assembly and its tools with tiny dimensions. The
schematic illustration of blanking-drawing combined process is shown in Fig.2. To simplify
the process, blank holding force (BHF) was not applied during the process. Instead of the
BHF, constant gap between the blank holder and the die flange surface, which is called
blank holder gap WBH, was designed in this die assembly. Additionally, to inhibit the
wrinkles at a flange part, process dimensions were determined based on the ratio of punch
diameter to the thickness Dp/t to be less than 20, referred to the report of Saotome et al. (19).
By using the above blank material, experimental equipment and tool set, progressive
circular deep drawing test were conducted for 300 times under a nonlubricated condition.

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The drawing speed was 1.0mm/s for milli-scale test and 0.4mm/s for micro-scale test. To
evaluate the transition of frictional behavior in both scales, a punch force was measured by
the load cells installed under the drawing punch. Additionally, to evaluate the transition of
surface state of dies, surface images in both scales were obtained by a digital optical
microscopy (VHX-1000, Keyence Co.) and the confocal laser scanning microscopy.

Table 2 Tool dimensions of progressive dry deep drawing test in milli- and micro- scales
Milli-scale (=1) Micro- scale (=1/6)
Blank thickness t0 /m 300 50
Blank diameter db /m 9600 1600
Die diameter Dd/m 5820 970
Punch diameter Dp/m 5100 850
Dir corner radius Rd/m 1500 250
Punch corner radius Rp /m 1200 200
Blank holder gap WBH/m 420 70

Blanking punch-
Drawing die
Initial State Blanking process Drawing process
Blanking punch Drawing die

WBH
Drawing punch

Blank
Blanking die
Blank holder

Drawing punch
Fig.2 Schematic illustrations of the sequential micro-blanking-drawing combined process
of ultrathin metal foils for micro-scale experiment

(a)Micro press machine systems (b)Die assembly and drawing tools

Fig.3 Appearance of the experimental systems and tools for the micro deep drawing

3. Experimental Results

3.1 Fabrication of milli- and micro-cups

Fig. 4 shows the appearance of the produced milli- and micro-scale cups. Geometrically
scaled drawn cups are fabricated successfully with the drawing ratio of 1.88 with stainless
steel foils.

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=1 (milli-scale)

=1/6
(micro-scale)

2mm
Fig.4 Appearance of drawn cups in milli-and micro- scale

3.2 Transition of normalized drawing force

Fig.5 shows the transition of maximum punch force in each scale. The variation of the
maximum punch forces is evaluated by dividing the average maximum punch force value of
initial 10 tests. Pmax/Pmax.ave.=1 suggests that there is no variation with increasing number of
the drawing test.
The maximum forces for the length scale of =1 increase with the number of drawing
tests until about 100 times and then the variation becomes stable until 300 times. On the
other hand for the =1/6, the maximum forces generally decrease with the number of
drawing tests until about 100 times, and then the forces become relatively constant with
large deviation until 300 times process. Thus, it is confirmed that the transition of the
forming force indicates the different tendency between the different scale dimensions.

1.5
Material: SUS304
Material: SUS304
Rate of variation in maximum punch force

1.4 Drawing ratio: DR=1.9

Drawing ratio: DR=1.9
Foil thickmess:
Foil thickness: t00=300 [m]
=300 x [m]
1.3 Punch diameter:
Punch diameter: DDdpdp=5.1 [mm]
=5.1 x [mm]
Drawing speed:
Drawing =0.4[mm/s]
speed: vvss=0.4[mm/s]
No lubricant
1.2 No lubricant

1.1 =1
Pmax/Pmax.ave.

1.0
1
0.9
0.8
0.7 =1/6
=1/6
0.6
=1
0.5
1 10 100 1000
Number of drawing tests Nd
Fig.5 Transition of maximum drawing force in progressive deep drawing test for different
scale dimensions

3.3 Transition of die surface quality

Fig.6 compares the surface images of corner radius of the drawing die. The images are
obtained from approximately 45 along to the corner angle. The centered white ring of the
images for the =1 (milli-scale) is the reflection from the light of optical lens and it is

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irrelevant to this observation. As clearly shown in Fig.6, the quantity of the adhesion of the
stainless steel for the =1 increases with increasing of the number of drawing tests from
Nd=50. Especially after Nd=100, the remarkable adhesion at the end of the corner radius is
observed.
On the other hand for the micro-scale of =1/6, the adhesion behavior is not remarkable
in contrast to the milli-scale. Whereas the surface seems to be smoothened until Nd=50,
after Nd=100, machined traces on the die in the circumferential direction seems to become
deeper and the adhesion of the work materials on the die can be observed after 300times
process. Fig.7 shows the variation of an arithmetic average roughness at die corner radius
for =1/6. The roughness value decreases until Nd=100, and increases at Nd=300 for both
radial and circumferential directions. Thus, the smoothening until Nd=100 are confirmed for
the micro-scale of =1/6.
Comparing with the transition of the forming force as above, it is found that the
transition tendency appears to be well corresponded to the die surface transition. The
increase of the drawing force for the =1 is apparently attributed to the plowing by the
adhered stainless steel particles on the tool surface. Meanwhile, the decrease of the punch
drawing force for the =1/6 seems to be explained by the smoothened surface of the
drawing tool.

Initial state After 50 times After 100 times After 300 times
Die radius inlet
=1

0.5mm 0.5mm 0.5mm

Die radius outlet
Die radius inlet
Adhesion
=1/6

30m 30m
Die radius outlet

Fig. 6 Surface images of the die corner radius during progressive deep drawing test in
milli-and micro- scale

Fig. 7 Variations of the arithmetic surface roughness of the die corner radius for micro-
scale progressive deep drawing test

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3.4 Transition of drawn cup wall surface

Fig.8 shows the surface images of the variation of the drawn cup wall surface. The clear
difference between different scales can be observed. The large contribution of the plowing
behavior is clearly demonstrated for the milli-scale process of =1. With increasing the
number of process, the deep scratch traces, which seems to be plowed by the accumulated
stainless steel on the die surface, is observed. While, for the drawn cup surface of
micro-scale of =1/6, although there are a few shallow plowing traces, the deep plowing
scratches as observed in =1 has not been observed, irrespective of the process number.
Therefore, it is proved that the adhered material on the die surface is largely responsible
for the frictional resistance during the forming, and the quantity of this adhered material is
relatively small in micro scale range. Assuming that the volume of the adhesion is equal to
the wear volume of the work material, the adhesive or abrasive wear volume of stainless
steel foil seems to be lower in micro scale range. Based on the scale dependent model
developed by Bhushan (21), since the number of trapped wear particle between contact area
has crucial influence on the friction, this low wear volume in micro scale would also make
important role to decrease the friction resistance during the process. In order to analyze the
difference in wear volume of the work material during the process, FEM calculation is
conducted in the following section.

(a)=1(Milli-scale) (b) =1/6(Micro-scale)

Fig. 8 Surface images of drawn cup wall during progressive deep drawing test in milli-and
micro- scale

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4. Adhesive Wear Volume Evaluation by Finite Element Analysis

4.1 Simulation setup

To evaluate the difference in wear volume of work material between different scale
dimensions as shown in experimental results, finite element (FE) analysis was carried out.
As the evaluations of adhesive or abrasive wear volume Vadh and Vabr, the following
empirical equations, proposed by Archard et al. (22) are well known.

k adh W l (1)
Vadh =
H

k abr W l W l tan (2)

Vabr = =
H H

where, kadh and kabr is the coefficient of wear for adhesive and abrasive wear,
respectively . W is the applied load, l is the sliding distance, H is the hardness of the softer
material of contact pair, is the angle of the slope of tool surface asperity. Focused on this
proportional relation with the sliding length, l, and applied force, W, Jensen et al. stated that
the tool wear is a function of both normal pressure, qN, and relative velocity, v, between the
sheet and the tool (23). In order to express the volume of wear for a section of the drawing
die profile by using FE analysis, they defined Zx ,as the index parameter which express the
volume of wear at a draw die area (x) ,given by the following equation,

t =t f t =t f
(3)
Z x Z xt qN ,n ,t vt
t =0 t =0

where Zxt is the wear volume index value at time t, qN,n,t is the normal stress for section n at
time t, vt is the tangential velocity for section n at time t, and tf is the ending time of the
FEM calculation. Since Zx values are proportional to the volume of the wear, it is useful to
relatively compare the wear volume in FEM calculation.
In the present study, assuming that the volume of the adhesion at die corner radius is
equal to the wear volume of the work material, we apply this evaluation methodology to
calculate the wear volume of the work material. In the calculation of Zx, because of the
importance of the normal stress qN, we modeled the surface asperity on the die surface to
simulate the localized surface pressure due to the surface asperity (20). The arcuate
configuration asperities were applied to the whole die surface element in the FE model as
schematically shown in Fig.9. A cyclic surface geometry was modeled as the height of the
profile, Rz, and a pitch width, wp, which both parameters are variable.
The tool and the material dimensions are the same dimensions as the experiment. The
axisymmetric FE mesh size of quadrilateral four-node three dimensional shell elements was
2m2.5m for micro-scale model and 6m7.5m for milli-scale model.
Simulation was carried out with LS-DYNA ver.970. The blank model was assumed as
isotropic elasto-plastic body, the die as an elastic body, and the punch and the blankholder
as rigid bodies. In order to evaluate only the influence of the scale dimension, the material
properties of the 300m thick stainless steel was used for both analysis of different
thickness. The static and kinetic friction coefficients between the blank and the tools were
assumed to be 0.10 and 0.08, which was verified with the experimental results of the
punch-stroke curves in 100th drawing process, as shown in Fig. 10. In this verification, the
roughness parameters are defined Rz=1.5m and wp=18m, based on the surface roughness
measurement of the drawing die after Nd=100.

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Dp
N nk
Blank
Bl a
Die
holder

Punch

vt ie s
e rit
as p
Blank
Blank a te
c u
(a) Dd Die
(b) Ar
Fig 9 FEM model for micro deep drawing considering surface roughness
(a) Schematic illustration of deep drawing model
(b) Example of equivalent stress distribution of die

3.5
Milli-scale (=1) deep drawing process
3.0 <Experiment>
After 100th drawing
2.5 process FEM
Punch load P [kN]

<FEM>
Surface roughness:
2.0
Rz=1.5mm Experiment
Roughness pitch:
1.5 wp=18mm

1.0

0.5 Experiment
FEM
0
0 1 2 3 4
Punch stroke Sp [mm]
Fig. 10 Comparison of experimental and simulated punch force-punch stroke curves
in milli-scale drawing process

4.2 Simulation results and discussion

Fig. 11 shows the maximum value of the normal pressure qN at each position angle of
die corner radius, where = 0 is the entrance of the die corner and = 90 is the end of the
corner. Since the equivalent stress is relative high at the peak of the asperity as shown in
Fig.9 (b), the peak of the following curves of the normal stress appears to be corresponded
to the high surface pressure at summit of single surface asperity. Although the number of
surface asperity is different between the scales, the surface pressure has almost no
difference.

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=1 (Milli-scale) Rz=0.3m wp=18 m

=1/6 (Micro-scale)

Normal stress qN [Gpa]

2mm 2mm

=1(milli) =1/6(micro)

Die inlet Angle of die corner radius [ ] Die outlet

Fig. 11 Maximum normal stress qN at each position on die corner during process in milli-
and micro-scale calculated by surface roughness FE model

Fig.12 shows the comparison data of wear volume index Zx in each scale dimension.
The maximum wear volume is indicated at the end of the die corner radius (approximately
70 to 80 of the corner). This result has a good agreement with the die surface observation,
which has strong adhesion at the end of the die corner radius as shown in Fig.6.
Furthermore, it should be noted that the difference in Zx value between each scale is
considerably large, which also corresponds to the experimental results. Additionally, the
pitch of the peaks of the Zx value curves corresponds to the pitch of the surface asperities
applied in the FE model. This indicates that the wear amount would be high at the peak of
the surface asperities. It can be seen at the accumulated stainless steel particle on the
machined traces of the die corner, as confirmed in Fig.6.
Considering from the slight difference in normal pressure qN as shown in Fig.11, this
lower value of wear amount index in micro scale seems to be due to the shorter sliding
distance according to the Eq. (3). As described in the Archards theoretical model, it is
obvious that due to the short absolute value of the sliding length in smaller scale could
result in lower wear volume.
Additionally, influence of the die surface roughness on the wear volume in each scale is
also evaluated to discuss the different tendency in the variation of the adhesive behavior of
the work material. Fig.13 shows the distribution of the peak value of the wear volume index
Zx for different die surface conditions in each scale. The input roughness parameters are
based on the surface roughness measurement at initial stage of Nd=1and Nd=100 for each
scale. Compared to the Zx value at initial stage, it is considerably increase at Nd=100 for
=1, while it slightly decreases for =1/6. This is clearly attributed to the initial roughness
value of the die surface. In other words, the larger amount of the wear generation for =1
results in the rougher surface due to the accumulated volume of the wear debris, and this
rough surface stimulates the increase of the wear amount of work material.

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Consequently, with the miniaturization of process dimension, the wear volume of the
work material becomes relative low due to the shorter sliding length and this would result in
the small variation of the surface roughness. Because of this small change or decrease of the
surface roughness value, the amount and its variation of the wear volume would decrease.
Thus, the contribution of plowing by adhered wear particles would remarkably decrease and
it could enhance the tool life in microforming.

Fig. 12 Wear volume index at each position on die corner during process in milli- and
micro-scale

Fig. 13 Comparison of wear volume index at each position for different input roughness
value in each scale dimension of =1 and =1/6

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5. Conclusion
This paper presents an experimental and numerical investigation of the scale
dependency in progressive adhesion behavior of the work material under dry sliding friction
in the micro deep drawing process. The scaled progressive dry micro deep drawing test up
to 300 times is carried out by using the two different process dimensions of the milli- and
the micro scale. The transition of the maximum punch forces shows the different tendency
between the scales. This tendency is strongly attributed to the adhered quantity of the work
material on the drawing die radius. The surface variation of the tool surface with increasing
the number of the drawing tests is relatively lower for the micro scale, while the milli scale
showed the strong adhesion of the work materials on the forming tool surface. The
calculation of the relative wear volume of work material by the FE analysis suggests that
the relative short sliding length and small variation in surface roughness for the micro scale
is responsible for the lower volume of wear of the work material. Thus, with the
miniaturization of the process dimension, the influence of the plowing by the adhered
particles on the frictional properties seems to decrease. The advantage in view of the tool
life in micro scale region is experimentally and numerically demonstrated.
Acknowledgement
This research was partially supported by The Ministry of Education, Culture, Sports,
Science and Technology (MEXT), Grant-in-Aid for JSPS fellow No.10502, 2010. The
authors also would like to express their gratefully acknowledge to the support from Mr.
Kuniyoshi ITO, Micro Fabrication Laboratory Llc., for the design of micro deep drawing
die assembly.

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