On the mechanics of metal imprinting by nominally flat and patterned rigid surfaces

•Insight into the mechanics of metal imprinting by nominally flat and patterned template surfaces.•Plastic flow of an isotropic strain hardening material indented by a patterned surface.•Pattern geometry, penetration depth, and friction effects on metal deformation.•Simulation results in dimensionless form illustrating the evolution of plasticity.•A computational framework for studying design and material effects in metal imprinting. Basic knowledge of the deformation behavior of fabricated components is of paramount importance in materials processing. Compared to other process methods, the mechanics of metal imprinting, especially at small scales, have received relatively less research attention. However, recent demands for tuning the properties of metal surfaces by forming undulated micropatterns have spurred interest in gaining additional insight into metal imprinting. The aim of this study, therefore, was to develop effective modeling capabilities that establish a ground base for exploring the mechanics of this process. Accordingly, a finite element analysis was performed to analyze the deformation of an elastic–plastic material exhibiting isotropic strain hardening imprinted by a rigid template with a nominally flat or patterned surface. Simulation results were obtained in the form of dimensionless quantities to elucidate the effects of pattern geometry, depth of imprinting, and friction on the evolution of plasticity in the deformed material and its plastic flow behavior into the pattern cavities. In addition to insight into the mechanics of the process, this study provides a computational methodology for adjusting key design and process parameters so as to enhance the efficiency of metal imprinting.