High Energy Rate Forming (Introduction)

This includes number of operations by which parts are produced at

extremely high pressure (some times called as high velocity form ing)

ÿ Some material which are not possible by conventional forming ca n be

formed by this method.

ÿ Advantages include low die costs, maintaining good tolerances and

minimum production costs.

ÿ Earlier application of this process was focused to forming thin sheet

metals

ÿ New applications of HERF include compacting metal powders,

forging, cold welding, extruding and cutting
High Energy Rate Forming methods
¸ Explosive Forming
¸ Electrohydraulic Forming
¸ Electromagnetic Forming

Explosive Forming
ÿ Explosive Forming has proved to be excellent method of utilizing
energy at a high rate, since the gas pressure and rate of detonation can
be carefully controlled.
ÿ Both high and low explosives can be used.
ÿ Low explosives such as explosive gases and gun cartridges are
commonly used for light duty applications.
ÿ Low explosive forming process is performed in a confining die which
completely encloses the workpiece.
ÿThis confinement maximizes the explosion energy, which is transferred
to the workpiece. (two examples)
An example of low explosive forming process
(confined combustible gas system)
An example of low explosive forming process (confined cartridge system)

ÿ Low explosive forming is useful for high precision applications

ÿ Low pressures 700 MPa limits its use to thin walled workpieces.
High explosives
ÿ High explosives generate pressures exceeding several thousand
megapascals in a span of 100 microseconds
ÿ Primacord is the most commonly used explosive because it can be easily
formed into shaped charges
ÿ High explosives are an economical form of energy for ex, a kg of
dynamite costs less than Rs1000 and can release more than 5 million
Joules of energy.
ÿ The shock waves sent off by high explosives is so great that the
explosion does not need to be confined as with low explosives.
ÿ Either air or water can be used as transfer medium.
ÿ Both flat and cylindrical configurations can be formed.
ÿ Water is preferred medium because of its incompressibility.
ÿ Incompressibility provides greater confinement of the charge and hence
a higher total impulse efficiency than that provided by air.
ÿ The size of charge needed to form a given part in water is 80% smaller
than the charge that would be required in air.
Two examples of high explosive forming in water medium
ÿ Dies used for explosive forming must withstand extremely high pressures
ÿ They are usually made of Mechanite or low carbon steel ( ductile metals)
ÿ Explosive forming can be accomplished by either with explosives in direct
contact with the part or with gap in between the two.
ÿ Contact system forms the highest forming rates but may fracture because of
non uniform distribution of forces.
ÿTo assure parts do not fracture the system is performed under water where
the forces are distributed more uniformly.
Electrohydraulic forming system