Development of progressive tool system for ultrasonic vibration assisted microforming
Gandjar Kiswanto, Hans Thiery Tjong, Siska Titik Dwiyati, Sugeng Supriadi, Wildan Zulfa Abdurrohman, Edward Joshua Patrianus Mendrofa, Raditya Aryaputra Adityawarmandownload PDF
Abstract. The demand for biodegradable implants is increasing as their efficiency in reducing the number of removal surgery after the healing process. However, the fabrication of magnesium miniplate by microforming is still a challenge due to its mechanical properties at room temperature and the micro-scale of the implant’s product. In this research, ultrasonic vibration is used to improve the production quality of micro-forming magnesium. The fabrication of miniplate magnesium includes micro blanking, micro punching, and micro stamping processes. The progressive system is adapted into the tool due to the constraint of design complexity. The simulation was conducted to validate the tool design and microforming process. The result of this research is a complete set of tool designs that is capable to integrate with Ultrasonic Vibration Assisted Microforming (UVAM) for producing miniplate implants with desired quality and accuracy. Furthermore, micro punching and microstamping stress decreased by around 30% when assisted with Ultrasonic Vibration.
Micro Forming, Tool, Ultrasonic Vibration
Published online 3/17/2023, 8 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Gandjar Kiswanto, Hans Thiery Tjong, Siska Titik Dwiyati, Sugeng Supriadi, Wildan Zulfa Abdurrohman, Edward Joshua Patrianus Mendrofa, Raditya Aryaputra Adityawarman, Development of progressive tool system for ultrasonic vibration assisted microforming, Materials Research Proceedings, Vol. 25, pp 297-304, 2023
The article was published as article 37 of the book Sheet Metal 2023
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
 S. Wiwanto, L.D. Sulistyani, F.D.E. Latief, S. Supriadi, B.P. Priosoeryanto, B.S. Latief, The experiment of magnesium ECAP miniplate as alternative biodegradable material (on male white New Zealand rabbits), in: 2018: p. 020013. https://doi.org/10.1063/1.5023947
 J. Hu, T. Shimizu, T. Yoshino, T. Shiratori, M. Yang, Ultrasonic dynamic impact effect on deformation of aluminum during micro-compression tests, J Mater Process Technol. 258 (2018) 144–154. https://doi.org/10.1016/j.jmatprotec.2018.03.021
 Y. Liu, C. Wang, H. Han, D. Shan, B. Guo, Investigation on effect of ultrasonic vibration on micro-blanking process of copper foil, The International Journal of Advanced Manufacturing Technology. 93 (2017) 2243–2249. https://doi.org/10.1007/s00170-017-0684-4
 S.V.S. Prasad, S.B. Prasad, K. Verma, R.K. Mishra, V. Kumar, S. Singh, The role and significance of Magnesium in modern day research-A review, Journal of Magnesium and Alloys. 10 (2022) 1–61. https://doi.org/10.1016/j.jma.2021.05.012
 M. Avedesian, H. Baker, eds., ASM Specialty Handbook: Magnesium and Magnesium Alloys, ASM International, n.d.
 J. Wang, N. Wang, X. Liu, J. Ding, X. Xia, X. Chen, W. Zhao, Compressive Deformation Behavior of Closed-Cell Micro-Pore Magnesium Composite Foam, Materials. 11 (2018) 731. https://doi.org/10.3390/ma11050731
 C. Cauthen, J. Pegues, J. Jr, M. Lugo, N. Shamsaei, Fatigue Micro-crack Growth and Modeling for Magnesium Alloys, 2015.
 B.L. Mordike, T. Ebert, Magnesium Properties-applications-potential, 2001. www.elsevier.com/locate/msea
 A. Mahmudah, G. Kiswanto, Development and Measurement of 5 kN -Forming Machine, Journal of Energy, Mechanical, Material and Manufacturing Engineering. 1 (2017). https://doi.org/10.22219/jemmme.v1i1.4474
 Y. Lou, X. Liu, J. He, M. Long, Ultrasonic-assisted extrusion of ZK60 Mg alloy micropins at room temperature, Ultrasonics. 83 (2018) 194–202. https://doi.org/10.1016/j.ultras.2017.03.012
 G. Kiswanto, S. Supriadi, S. Titik Dwiyati, Challenge in magnesium microforming, IOP Conf Ser Mater Sci Eng. 1070 (2021) 012121. https://doi.org/10.1088/1757-899X/1070/1/012121.
 A. Messner, U. Engel, R. Kals, F. Vollertsen, Size effect in the FE-simulation of micro-forming processes, J Mater Process Technol. 45 (1994) 371–376. https://doi.org/10.1016/0924-0136(94)90368-9
 A. Mahmudah, G. Kiswanto, D. Priadi, Fabrication of punch and die of micro-blanking tool, IOP Conf Ser Mater Sci Eng. 215 (2017) 012040. https://doi.org/10.1088/1757-899X/215/1/012040
 V. Boljanovic, Sheet Metal Forming Processes and Die Design Second Edition, 2019.
 J.L. Li, L.L. Jing, M. Chen, An FEM study on residual stresses induced by high-speed end-milling of hardened steel SKD11, J Mater Process Technol. 209 (2009) 4515–4520. https://doi.org/10.1016/j.jmatprotec.2008.10.042
 D.J. Steinberg, Equation of state and strength properties of selected materials, Lawrence Livermore National Laboratories, n.d.
 W. Toqueboeuf, B. Mortaigne, C. Cottenot, Dynamic Behaviour of Polycarbonate/Polyurethane Multi-Layer for Transparent Armor, Le Journal de Physique IV. 07 (1997) C3-499-C3-504. https://doi.org/10.1051/jp4:1997386
 J. Zhao, H. Su, C. Wu, The effect of ultrasonic vibration on stress-strain relations during compression tests of aluminum alloys, Journal of Materials Research and Technology. 9 (2020) 14895–14906. https://doi.org/10.1016/j.jmrt.2020.10.094