A Comprehensive Examination of Key Characteristics Influencing the Micro-Extrusion Process for Pure Copper Cross-Shaped Couplings

In the manufacturing of micro-scale components, geometric dimensional accuracy and product quality are critical factors that directly influence both production costs and efficiency. To meet the growing demands in this field, micro-extrusion technology has been developed and extensively applied, particularly in mass and bulk production. This technology is considered an optimal solution for improving dimensional accuracy, enhancing mechanical properties, increasing production efficiency, and reducing costs compared to traditional methods, while also aligning with the current trends of modern industrial development. This study investigates the influence of temperature and friction on forming force, formability, and product quality during the micro-extrusion process. A combined approach of simulation and experimentation was utilized to form cross-shaped coupling components using pure copper as the material. The results indicate a significant relationship between temperature, friction coefficient, and forming force. Furthermore, 550 °C is identified as the most suitable temperature for hot forming, providing a balance between force reduction and product quality. These insights enhance the predictability and control of the micro-extrusion process and contribute to reducing production defects. Ultimately, the findings support wider implementation of micro-extrusion in the manufacturing of high-accuracy small-scale parts and align with modern trends emphasizing miniaturization, automation, and cost efficiency.