With the increasing trend toward product miniaturization, progressive forming has been widely used in fabricating meso‑/micro-scaled parts using sheet metals. However, there are difficulties for such processes and sheet metals to be employed to manufacture the parts and components with local rotating features, and their rotating axis is not in the extruding/forming direction. In this work, a progressive forming process directly using metal wires was first developed. The constitutive model using the brass CuZn35 wires of different diameters (0.4–1.2 mm) as a case study material with different grain sizes (30.9–159.2 μm) was developed. By using the multi-scaled fork-shaped parts with flat tines and cylindrical heads as case micro-parts to be micro-formed, the dimensional errors induced by springback increased with the grain size while decreasing as the specimen size increased. The surface quality deteriorates with the increase in grain size, and the micro-cracks form more easily on the side surface of micro-parts with larger grains. The undesired geometry issue of the fabricated parts was overcome by optimizing the tool design. This work further expands the promising application of the progressive forming process in the high-efficiency fabrication of meso‑/micro-scaled parts with irregular features.

随着产品小型化的趋势不断增强，渐进成形已广泛用于使用金属板材制造细观/微型零件。然而，采用这种工艺和钣金制造具有局部旋转特征的零件和组件存在困难，并且它们的旋转轴不在挤压/成形方向上。在这项工作中，首先开发了一种直接使用金属线材的渐进成型工艺。开发了使用不同直径 (0.4–1.2 mm) 的黄铜 CuZn35 线作为具有不同晶粒尺寸 (30.9–159.2 μm) 的案例研究材料的本构模型。通过使用带有扁平齿和圆柱头的多刻度叉形零件作为外壳微型零件进行微成型，回弹引起的尺寸误差随着晶粒尺寸的增大而增大，随着试样尺寸的增大而减小。表面质量随着晶粒尺寸的增大而变差，晶粒较大的微零件侧面更容易形成微裂纹。通过优化工具设计克服了制造零件的不良几何问题。这项工作进一步扩展了渐进成形工艺在高效制造具有不规则特征的细观/微观尺寸部件中的应用前景。