Formability and fracture of metallic sheet materials in microscale punching processes using laser-accelerated flyer impact

Laser-accelerated metallic flyers can be used in microscale manufacturing processes by providing high-speed impact and shockwave to target materials. This study conducted microscale punching experiments using a laser-accelerated flyer for various mold sizes, workpiece thicknesses, and flyer thicknesses to investigate performance and failure characteristics of the punching process. In the case of a single flyer impact, punching was successful when the ratio of mold diameter to workpiece thickness exceeded 3. High-speed punching advantages, which improve punching quality as the shear zone increases and burrs become smaller, were validated. When flyer thickness was significantly reduced, punching performance deteriorated although higher speed could be realized, because the thinner flyer was difficult to maintain flatness during acceleration, resulting in inefficient forming pressure transfer to the workpiece. When the ratio of mold diameter to workpiece thickness was less than 3, punching was achieved through multiple flyer impacts. However, pressure transfer efficiency from the flyer to the workpiece was further reduced. Thus, punching performance could be improved by reducing the relative size of the flyer to the mold diameter.