Investigation of a combined embossing and blanking process using laser shock wave

Laser shock forming is a three-dimensional forming technique. It is promising for achieving precise, well-controlled, low-cost, high efficiency 3D metallic microstructures. In this research, a combined process of embossing and blanking is studied by experimental and simulation methods, in which the embossing and blanking of copper sheets are performed at the same time in only one operation. In order to obtain multi-workpieces in one process, overlapping laser spots were applied in the experiment. Moreover, the influence of laser energies on the work pieces were considered, and the results show that the micro features on the boss surface of the mold were successfully replicated on the blanking copper foil surface with the suitable energy. By evaluating the surface roughness data, it can imply that the work piece surface can fit the mold surface. Meanwhile, the process of the combined embossing and blanking was also studied by numerical simulation, the simulation results show that the finite element analysis can predict the final shape of work piece properly, verifying the feasibility of this process.