Improvement of product quality is required more than ever for mass production of micro formed parts.
The process of micro multi-point forming with cushion has been simulated in this paper by finite element
model which incorporates a constitutive relation with consideration of size effect. The effect of the cushion
material, cushion thickness and coefficient of friction on the surface quality of the deformed sheet
has been investigated. It has been found that a proper selection of the cushion material and optimum
cushion thickness can significantly improve the surface quality. In addition, this paper also discusses the
influence of the cushion material and coefficient of friction on the sheet thickness distribution. Better
surface quality and thickness distribution can be obtained with good lubricating condition.