Development of a novel resistance heating system for microforming using surface-modified dies and evaluation of its heating property

Abstract

For this study, a novel resistance heating system for microforming was developed using surfaces of forming dies as heating resources. The electrical resistance of the die surfaces was designed and the hard-coating material AlCrSiN was selected to coat the die surfaces for heating. To clarify the effects of the thickness and modified surfaces on heating efficiency, the temperature and stress reduction were evaluated in a micro-compression test using dies coated with 0.5 and 1 μm AlCrSiN films. Furthermore, the formability was also demonstrated using 1 μm thick AlCrSiN-coated tools in a microforging test. By applying surface-modified dies to the forming processes, we found that not only was the heating efficiency improved, but also the dependence of heating on the product’s shape and the material’s electrical properties was reduced.