Numerical and experimental investigation on the formability of stainless steel-copper composites during micro deep drawing

Abstract

In the present study, two-layered stainless steel-copper composites with a thickness of 50 µm were initially subjected to annealing at 800, 900 and 1000 °C for 5 min, respectively, to achieve diverse microstructural features. Then the influence of annealing temperature on the formability of stainless steel-copper composites and the quality of micro composite cups manufactured by micro deep drawing (MDD) were investigated, and the underlying mechanism was analyzed. Three finite element (FE) models, including basic FE model, Voronoi FE model and surface morphological FE model, were developed to analyze the forming performance of stainless steel-copper composites during MDD. The results show that the stainless steel-copper composites annealed at 900 °C possess the best plasticity owing to the homogeneous and refined microstructure in both stainless steel and copper matrixes, and the micro composite cup with specimen annealed at 900 °C exhibits a uniform wall thickness as well as high surface quality with the fewest wrinkles. The results obtained from the surface morphological FE model considering material inhomogeneity and surface morphology of the composites are the closest to the experimental results compared to the basic and Voronoi FE model. During MDD process, the drawing forces decrease with increasing annealing temperature as a consequence of the strength reduction.

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