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( 1 )
Where U is st rain energy
(
)
+ (
)
+ (
.( 2)
(
)
+ (
)
+ (
)
. ( 3)
For most st rain hardening mat erials: -
= K
. ( 4)
K is const ant and n is t he st rain hardening exponent
For st rain hardeni ng mat erial
U =
( 5)
Ef f ect of ex pl osi v e st andof f di st an ce on st r ai n di st r i b ut i on
i n t he ex pl osi v e f or mi ng of f l at ci r cu l ar bl ank s
Using cent rally l ocat ed charge as shown in t he f ig. 3 t o explosivel y
f orm of a fl at circular blank, t he dist ri but ion of st rain across a
diamet er of t he blank will vary wit h t he rat io of st andof f dist ance,
( L) t o t he diamet er of t he die opening, ( D) .
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Explosive metal forming Dr. Hani Aziz Ameen
Fig. 3
Est i mat i ng of t ot al st r ai n ener gy an d t h e w ei g ht ch ar ge r eq ui r ed
f or an ex pl osi v el y f or med dome i n si ngl e sh ot .
a- Comput ing t he value of D
o
and B
o
Do= D + r e (6)
Bo= 4w
+ B
. . (7)
R
w
W
1
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Explosive metal forming Dr. Hani Aziz Ameen
Techni cal Col l ege Baghdad Ir aq- Di es and Tool s Eng. Dept .
1 1 4(
(8)
b- Calculat ing of max. permissible dept h of draw
w
( 2n + 1) ( 4n + 13) . ( 9)
A- I f w
) should be
calculat ed as follows: -
U
=
( Bo D
) .. ( 10)
w
= w | U
| + 0.57 r
. . ( 11)
U
4
D
2
h
o
K
n+1
jln j1 + 4(
w
D
) [ [
n+1
. . (12)
U
F
= [
3
3
n+1
K
n( n+1)
h
o
j[
Bo-B
2
Bo[
n+1
_[
D
o
2
-2n
[
Bo
2
-2n
_.( 13)
d- Est imat ing of t he charge weight using t he geomet rical met hod: -
W=
2 U
T
1
( 1-cos) c
.( 14)
e = specific ene r gy of t he char ge
1
1
= 4.23 3.7 [
L
for
L
0.5 .. ( 15)
1
1
= 4.02 3.7 [
L
for
L
1 . ( 16)
cos = [t an
-1
D
2L
. . ( 17)
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Explosive metal forming Dr. Hani Aziz Ameen
Techni cal Col l ege Baghdad Ir aq- Di es and Tool s Eng. Dept .
= t an
-1
D
2L
.( 18)
e- I f B condit ion is sat isf ied one must comput e t he dept h of t he draw
of t he f irst shot and t he required weight exact ly as in t he st ep c
and d t hen must comput e t he dept h of t he dome and weight of t he
charge for second shot as f ollows: -
Mul t i ple shot explosive formi ng
I f h
1
is a mat erial t hi ckness af t er f irst shot and
h
2
is a mat erial t hickness af t er second shot t hen: -
h
1
h
2
=
R
2
w
2
R
1
w
1
. . ( 19)
h
1
h
2
=
1+
4v
1
2
D
2
1+
4v
2
2
D
2
( 20)
t he t hickness st rain
t
i s t hen given by: -
t
= ln
h
1
h
2
= ln
1 +
4w
1
2
D
2
1 +
4w
2
2
D
2
. (21)
cII
= t
w
2
w
1
2
char ge
Fi g.5 M ul t i pl e shot f or mi ng seq uen ce
h
1
h
2
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Explosive metal forming Dr. Hani Aziz Ameen
Techni cal Col l ege Baghdad Ir aq- Di es and Tool s Eng. Dept .
cII
= ln
1+
4v
1
2
D
2
1+
4v
2
2
D
2
.( 22)
Usi ng Hill formula ( e
=
1
2
( 2n + 1) ) for max. per missibl e bi- axial
st rain energy and equat ing it t o t he max. ef fect ive st rain at
t he end of t he second shot we get : -
1+
4v
1
2
D
2
1+
4v
2
2
D
2
= cxp j
4
11
( 2n + 1) [ ( 23)
Solving f or
w
2
D
we have
w
2
D
=
1
2
_
[1 +
4w
1
2
D
2
exp j
4
11
( 2n + 1) [ 1 ( 24)
Aft e r obt aining w2 , now we can calculat e s t r ain ener gy per unit volume
for t he second shot:-
U
2
=
K
n+ 1
_ln (
1 +
4w
2
2
D
2
1 +
4w
1
2
D
2
_
n + 1
.( 25)
t he t ot al st rai n energy of t he deformat ion can be calcul at ed by: -
( U
T
)
2
=
4
D
2
h
o
K
n+1
_ln (
1+
4v
2
2
D
2
1+
4v
1
2
D
2
_
n+1
( 26)
The expl osi ve energy ( E
T
)
2
deli vered t o t he bl ank by t he second
shot may be est imat ed as foll ows: -
( E
T
)
2
=
1
2
2
( 1 cos
2
) W
2
e . ( 27)
Where
2
is defi ned i n fi gure 5, w
2
is t he weight of second charge
and e is t he speci fic energy of t he expl osi ve i. e. energy per uni t
wei ght of t he charge.
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Explosive metal forming Dr. Hani Aziz Ameen
Techni cal Col l ege Baghdad Ir aq- Di es and Tool s Eng. Dept .
Case study of domed shape forming
Estimate the required (TNT) charge weight (W) to produce flanged dome
shape made of Aluminium alloy 2014-0 with the following dimensions:-
B =3.3m , D = 3m, w = 1m, h
o
= 0.02m and r
e
=0.01m.
-----------------------------------------------------------------------------
Solution
From tables:
K = 320.4Mpa, n = 0.244,
1
1
= 4.23 3.7 [
L
= 3.6 and
e = 0.393 10
6
m.N/Kg and chose
L
=
1
6
= 0.167.
1- Do= D + 2 x r e = 3.02 m.
2- Bo= 4w
2
+ B
2
= 3.86 m, is a blank diameter.
3- To calculat e max. pe r mis sible dept h:
w
1
=
D
11
( 2n + 1) ( 4n + 13) =1.072 m.
w
1
> w so we need just a single shot to achieve the process.
4. w
= w j
B
o
2D
o
( B
o
B) [ + 0.57 r
c
= 0.64 m.(but we apply w = 1m).
5. To calculate the energy required to form the dome:
U
D
=
4
D
2
h
o
K
n+1
jln j1 + 4(
w
D
) [ [
n+1
= 10.5 10
6
N.m.
6. To calculate the energy required to form the flange:
U
F
= [
3
3
n+1
K
n( n+1)
h
o
j[
Bo-B
2
Bo[
n+1
_[
D
o
2
-2n
[
Bo
2
-2n
_
= 0.98 10
6
N.m
The total energy required to form the dome:
E
T
= U
T
= U
D
+ U
F
= 11.48 10
6
N. m.
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Explosive metal forming Dr. Hani Aziz Ameen
Techni cal Col l ege Baghdad Ir aq- Di es and Tool s Eng. Dept .
So the explosive charge (W) can be calculated :
W =
2L
T
1
( 1cos
1
) e
1
= tan
-1
[
D
2L
Since
L
D
= 1.67
L= 0.5 m
So W required is 17 kg.
Conclusions and disruptions
In explosive metal forming chemical energy from the explosive is used to
generate shock waves through a medium which are direct to the workpiece at
very high velocities. This process was mostly used to form large and bulky
components typically for military and aerospace components and now can be
used for small parts with complex shapes and low capital investment also the
ability to vary energy levels over wide ranges provides greater capabilities
than conventional forming methods. The process can be achieved by the
simplest requirements such as one side die, the workpiece and an explosive
charge.
Beside all advantage with some limitations and although it is not new process
but one feel that the information about explosive forming is still not enough,
may be due to the difficulty of understanding what happens exactly during the
process so someone trying to simulate the method, another reason is dealing
with explosive so the informations are not available and forbidden.
To provide a fully picture about explosive forming there must be additional
information available.
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Explosive metal forming Dr. Hani Aziz Ameen
Exampl es t hat have been pr oduced by expl osi ve f or mi ng
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Explosive metal forming Dr. Hani Aziz Ameen
References
1. Herold, K.P.; Vovk, V.; Taran, V.; Vovk, A: Explosive forming of high-
strength sheet material. 10-th International conference Sheet Metal, Ulster, E;
April, 2003.
2. Hydroforming - Wikipedia, the free encyclopedia.
3. Taran, V.*; Vovk, V.* ; Sabelkin, V.**; Vovk, A.* . * Otto-von-Guericke-
University Magdeburg, Magdeburg, Germany** IMP, Mexico(Explosive
Forming of Metal Blanks).
4. Principals and practice of explosive metal working by A.A. EZRA.
The Aut hor
Dr . Hani Azi z Am een , Bi r t h dat e 1971 i n Baghdad- Ir aq, has Ph.D. i n
M echan i cal Engi neer i ng Appl i ed M ech ani cs f r om t he Un i ver si t y of
Techno l ogy Ir aq i n 1998. He has mor e t han 50 publ i shed paper s and he i s an
exper t i n t h e ANSYS sof t war e and f i ni t e el emen t anal ysi s.
Wor ki n g i n sever al uni ver si t i es and col l eges (Technol ogy Un i ver si t y-
Al Nahr een Uni ver si t y- Ti kr i t Uni ver si t y Techni cal Col l ege Al M u sai b).
And now h e i s Asst . Pr of essor i n t he Techni cal Co l l ege Baghdad / Di es and
Too l s Engi neer i ng Depar t men t .
E-mai l : hani azi zameen@yahoo.com
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