Precision forming of micro parts

Precision engineering is a subfield of mechanical engineering. The process involves designing and using of machineries, fixtures or other structures with low tolerances but high accuracies for fabrication. Fine blanking is one of the processes evolved from the conventional blanking process. The aim of this experiment is to compare, contrast and recommend the best combination of fixture, aluminium foil thickness and punch diameter that would produce micro parts closest to the dimensional requirements. The hand fixture represents conventional blanking process whereas toggle press fixture represents fine blanking process. It will involve specimens blanking from different foil thicknesses using the fixtures, with different punches. The specimen’s diameter and burr height measurements will be obtained and analyzed for comparisons. There were a total of 48 specimens produced. The measurements and image taking were done using the Confocal microscope and Scanning Electron microscope respectively. The results were first analyzed and compared within their own process type, followed by taking the best combination from each type to cross compare for the final choice. It was gathered that conventional blanking results conformed to the theory that die clearances affect deformation zone proportionally; but inversely for the burr. Hence based on the theory, one best combination was obtained. For fine blanking process, with the help of an ejector and V-ring, the diameter accuracy was comparable to the conventional’s best. However its burr features were much superior and thus the final choice was decided to be from the fine blanking process.Bachelor of Engineering (Mechanical Engineering