Unit 6
Advanced Forming Processes
High velocity metal forming techniques
Explosive forming,
Electro hydraulic
Electromagnetic forming.
High velocity forming (HVF) involves imparting a high kinetic energy
to the work piece by accelerating it to a highly velocity, before it is
made to hit the appropriate die. In these forming processes large
amount of energy is applied for a very short interval of time.
Advantages of HVF and HERF processes
1. Increase in ultimate strength of about 50% for some metals.
2. Ability to produce many types of complicated parts economically.
3. High accuracy in size and shape of the components made can be
achieved.
4. Spring back elimination and permanent set in even the most difficult
to form metals.
Limitations:
The limitation of these processes is the need for skilled personnel.
EXPLOSIVE FORMING
It is type of process in which the explosive charge is detonated. High
energy is produced nthe metal which leads to very rapid acceleration
over a very short period of time and the metal is formed into a die
shape due to kinetic energy.
Low explosives
Low explosives are smokeless powder and black powder.
Low explosives on burning do not produce high pressure and hence not
commonly used in explosive formation operations. Pressure generated
0.5 kg/m2.
High explosives
They are quite commonly used in explosive forming process. These
explosives react by the process of detonation which takes place almost
independently of the surface area of the change or pressure of
surrounding medium. The pressure generated as high as 3*10^5 kg/cm
Working Principle of Explosive Forming Process:
Explosive energy used as metal forming Sheet-metal blank is
clamped over a die
Assembly is immersed in a tank with water Rapid conversion of
explosive charge into gas
generates a shock wave. The pressure of this wave is sufficient to
form sheet metals (a) explosive
forming process. (b) confined method of explosive bulging of tubes.
There are three different explosive forming techniques now being
used: free forming, bulkhead forming, and cylinder forming.
All are shown schematically in Figure H.1. Both free
forming and bulkhead forming allow the work-piece to
be heated before forming. Although air
can be used as a coupling medium between the
explosive and the workpiece, in most cases water
is used. Efficiency in air is approximately 4%; in water,
33%. Changes in mechanical properties
caused by explosive forming correlate closely with
those obtained in material cold-worked to the
same degree. In HERF of nickel alloys and the 300 series
of stainless steel, strength and hardness
are increased and, as expected, ductility is decreased
Benefits of explosive forming
Explosive forming proves to be beneficial in many ways:-
(a) It is used for performing operations on very large parts where the
forces required arebeyond the capacity of most conventional
presses.
(b) It is used for forming sheet metal parts in different materials and to
new shapes.
(c) It has provided the means for fabricating large structures without
first building, eitherlarge precision machine tools or massive
complicated die sets.
(d) It is quite successful for low volume production of large often
complex parts of tough metals.
Advantages of explosive forming
The advantages of explosives forming are:-
(a) by this process sheet metal are formed into shapes which cannot
be produced economically by other conventional process.
(b) Investment cost in dies is low.
(c) Components can be made to close tolerances.
(d) Tough materials as well as ductile materials can be explosive
formed.
(e) One die can be used to produce parts in varying thickness
Disadvantages of explosive forming
The disadvantages are:-
(a) The process should be conducted at safe and remote places
because of lots of sound and
noise is produced and precautions are to be taken as explosion
hazards exit.
(b) Where the impact strength and stress corrosion resistance are
important then
explosively produced parts could have disadvantage
Applications of explosives forming
Applications of explosives forming are:-
(a) It is used for forming of dished parts.
(b) It can be used to produce components having a very
wide range of sizes and shapes.
(c) It is used for the production of large parts with
reentrant sections, which are not possible
by conventional methods.
(d) Engraving
(e) Fracturing
(f) Welding
(g) Hardening
ELECTRO HYDRAULIC FORMING (EHF):
Electro hydraulic forming, also called electric discharge forming,
is a unique high energyforming process for sheet metal. This
manufacturing process uses the energy from the combustion of a
thin metal wire. Two electrodes, with a wire connecting them, are
submersed in
liquid. The work is set up similar to the standoff system described
above, however this process is applicable to relatively smaller
parts. A sheet metal blank is secured on top of the mold with
aring clamp and a vacuum is created in the die cavity under the
blank. Electrical energy is stored
in a capacitor bank. The electricity is discharged through the
electrodes and the wire, instantly
vaporizing the wire, creating a shock wave that travels through
the water.
This shock wave forms
the sheet metal to the mold cavity. Electro hydraulic forming
produces a shock wave of relatively
low magnitude and is best suited for thinner work. The wire
needs to be replaced after every
operation. Electro hydraulic forming may be considered to have
a low production rate.
The principle of electro-hydraulic forming
The principle used in electro hydraulic process forming can be
stated as the ability to generate
high intensity shocks waves by discharging the stored electrical
energy across electrodes
submerged in a liquid medium.
Advantages of electro-hydraulic forming
The advantages of lector hydraulic forming are;-
(a) It is a versatile process and can be used for the forming of
tubular or dished shaped parts
very successfully.
(b) The requirement of only a female die results in substantial
reductions of tooling costs.
This, combined with the possibility of using low cost die materials,
makes short run and
prototype production economically more attractive.
(c) Large amounts of energy can be directed to isolated areas of the
work piece.
Similarities between electro hydraulic forming and explosive
forming
The similarities are:-
(a) The deformation speed is same in both cases.
(b) Both processes can be successfully used for making tubular and
dished shaped parts.
The various electro – hydraulic forming process variables
The various variables which affect the efficiency of electro-forming
system are:-
(a) Electrode gap width
(b) Stand-off distance
(c) Charge energy
(d) Hydrostatic head
The limitations of electro hydraulic forming process
The limitations are :-
(a) This process is suitable only for making relatively smaller
components because of
maximum energy that can be generated by this process.
(b) Materials with critical impact velocities less than 30m/s not
suitable for this method.
Similarities between electro hydraulic forming and explosive
forming
The similarities are:-
(a) The deformation speed is same in both cases.
(b) Both processes can be successfully used for making tubular and
dished shaped parts.
Difference between electro- hydraulic forming and explosive
forming
The difference between them are;-
(a) Electro hydraulic process is used for the production of smaller
components in large
number whereas explosive forming is used to produce large
components to be
produce in smaller number.
(b) The capital cost of electro hydraulic forming unit is more than the
capacity of
explosive forming unit.
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