Material Forming

Processes

High Velocity Forming

(HVF)

High Velocity forming: Explosive forming; electro-hydraulic forming, electromagnetic forming;

shock tube forming.

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• CAT 2
(a) (i) Explain briefly the “high velocity rate forming” process in metalworking.
• (ii) Using an explosive charge, illustrate and explain briefly the formation of
(1) a tubing section
(2) a flat disc into a dome

(iii) Using bulging of a tubing section, illustrate and explain briefly the electromagnetic hydraulic forming method.
(12 marks)
• (b) In the bulging operation of a cylindrical shape the following information is given:
• R˳= original radius of the tubing
• R = the final cylindrical radius
• t = the final thickness
• L = the deformed length
(i) Sketch formed and bulged tubing sections
(ii) Determine the volume of the metal of the bulged tubing
(iii) Determine the circumferential strain of the outside diameter of the bulged tubing
(iv) Determine the total deformation energy given that the stress-strain curve of the metal is given by σ =Kεn
• where σ is the true stress and ε is the natural strain; K and n are constants.
(8 marks)

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 Overview
▪ Definition
▪ Explosive forming
▪ Electro-hydraulic forming
▪ Magnetic pulse forming or Electromagnetic forming
▪ Shock tube forming

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4
 Introduction
▪ In these forming processes large amount of energy is applied for a very short interval
of time
▪ Many metals tend to deform more readily under extra – fast application of load
which make these processes useful
▪ The parts are formed at a rapid rate, and thus called high – velocity forming processes.
▪ Advantages
▪ Die costs are low
▪ Complex shapes can be manufactured easily.
▪ Easy maintenance of tolerances
▪ Possibility of forming most metals
▪ Material does not show spring-back effect
▪ The production cost of components by such processes is low.

▪ Limitation of these processes is the need for skilled personnel

▪ 3 main types: explosive forming, magnetic forming, and electrohydraulic forming.

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 Explosive Forming
❑Involves shaping of materials by exertion of sudden
pressures from explosion of a chemical charge.
❑The shock wave causes the metal to take the shape of
the die.
❑High explosive chemical used: TNT, RDX, Gasesous
mixtures & propellants.
❑There are two techniques of high –explosive forming:
✓Stand – off technique or Unconfined Type
✓Contact technique or Confined Typed

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Explosive
Uses shockwave (pressure) to force formation
Material must be ductile at high rate of deformation
 Standoff Explosive Forming

Principle & Steps

▪ The work is firmly supported on the die and the die cavity is evacuated.
▪ A definite quantity of explosive is placed suitably in water medium at a
definite standoff distance from the work.
▪ On detonation of the explosive charge, a pressure pulse (or a shock wave) of very high
intensity is produced.
▪ A gas bubble is also produced which expands spherically and
then collapses.
▪ When the pressure pulse impinges against the work piece, the metal is deformed into
the die with as high velocity as 120 m/s.
▪ The vacuum is necessary in the die to prevent adiabatic heating
of the work which may lead to oxidation or melting.

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 Standoff Explosive Forming

Sequence of underwater explosive forming operations.(i) explosive charge is set in

position (ii) pressure pulse and gas bubble are formed as the detonation of charge
occurs, (iii) work piece is deformed, and (iv) gas bubbles vent at the surface of water.

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 Standoff Explosive Forming
Advantages
▪ Shock wave is efficiently transmitted through water and energy is transmitted effectively on
the work
▪ Less noise
▪ Less probability of damage to work.
▪ Large and thick parts can be easily formed
▪ Economical, when compared to a hydraulic press
▪ The process is versatile – a large variety of shapes can be formed, no limit to the size of the
work piece
▪ suitable for low – quantity production as well
▪ The process has been successfully used to form steel plates 25 mm thick x 4 m
diameter and to bulge steel tubes as thick as 25 mm.
Limitations
▪ Optimum SOD is essential for proper forming operation.
▪ Vacuum is essential and hence it adds to the cost.
▪ Dies must be larger and thicker to withstand shocks.
▪ Not suitable for small and thin works.
▪ Explosives must be carefully handled according to the regulations of the government.
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 Contact Explosive Forming

Principle & Steps

✓ The explosive charge in the form of cartridge is
held in direct contact with the work piece while the
detonation is initiated.
✓ The detonation builds up extremely high pressures (up to
30,000MPa) on the surface of the work piece resulting in
metal deformation, and possible fracture.
✓ The process is used often for bulging tubes

Applications of Explosive Forming

▪ Ship building,
▪ Radar dish
▪ Elliptical domes in space applications
▪ aerospace industries & production of automotive related components.
▪ In limited – production prototype forming and for forming large size components for which
conventional tooling costs are prohibitively high.

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 Electro Magnetic Forming or Magnetic Pulse Forming

▪ In this method the electrical energy Magnetic-Pulse Metal Forming

stored in a capacitor bank is used to • Uses magnetic force discharged from
produce opposing magnetic fields around a magnetic coil
a tubular work piece, surrounded by • Material must have electrical
current carrying coils. conductivity
▪ The coil is firmly held and hence the work
piece collapses into the die cavity due to
magnetic repelling force, thus assuming
die shape.

▪ Applications:
➢ Crimping of coils, tubes, wires
➢ Bending of tubes into complex shapes
➢ Bulging of thin tubes.
▪ The work coils needed for different
applications vary although the same
power source may be used. 12
 Electro Magnetic Forming or Magnetic Pulse Forming

Principle
▪ This process is based on the principle stated by Lorentz force law that the electromagnetic
field of an induced current always opposes the electromagnetic field of the inducing
current.
▪ In this method a large capacitor bank is discharged producing a current charge
through a coiled conductor.
▪ If the coil has been placed within a conductive cylinder, around a cylinder or
adjacent to a flat sheet of metal, then the discharge induces a secondary current in
the workpiece.
▪ This secondary current further causes it to be repelled from the coil and conformed to a
die or mating work piece.
▪ The process is very rapid and is used primarily to expand or contract tubing or to
permanently assemble component

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 Electro Magnetic Forming or Magnetic Pulse Forming

Process Variants
• Depending on the geometry and the alignment of tool and workpiece, three
process variants can be distinguished. These are
• (i) electromagnetic compression of tubes and hollow profiles by means of
an inductor enclosing the workpiece,

Swaging

(ii) electromagnetic sheet forming, for which an inductor is positioned in

close proximity of a flat semi-finished part or a preformed component.

Embossing
or blanking

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 Electro Magnetic Forming or Magnetic Pulse Forming

Process Variants
• (iii) electromagnetic expansion of tubes and hollow profiles by means of an
inductor positioned within the workpiece

Expanding

▪ This work piece is placed in a coil. A high charging voltage is supplied for a short time to a bank of
capacitors connected in parallel.
▪ When the charging is complete, which takes very little time, a high voltage switch triggers the stored
electrical energy through the coil.
▪ A high – intensity magnetic field is established which induces eddy currents into the conductive work
piece, resulting in the establishment of another magnetic
field.
▪ The forces produced by the two magnetic fields oppose each other with the consequence that
there is a repelling force between the coil and the tubular work piece that causes permanent deformation
of the work piece.
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 Electro Magnetic Forming or Magnetic Pulse Forming

Advantages
▪ Suitable for small tubes
▪ Operations like collapsing, bending and crimping can be
▪ easily done.
▪ Electrical energy applied can be precisely controlled
▪ and hence the process is accurately controlled.
▪ The process is safer compared to explosive forming.
▪ Wide range of applications.
Disadvantages :
• Applicable only for electrically conducting materials.
• Not suitable for large work pieces.
• Rigid clamping of primary coil is critical.
• Shorter life of the coil due to large forces acting on it.

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 Electro Hydraulic Forming

Introduction
• Also Known as Electrodischarge or Electroshape
or Electrospark Forming
• process in which electrical energy is converted into
mechanical energy
for the forming of metallic parts.
Process Principle
• Electro-hydraulic forming tools and processes,
produce a shockwave by creating a high voltage
discharge in a liquid that is in contact with the sheet
metal blank to be formed.
• The shockwave in the liquid is propagated
towards the blank and causes the blank to be
deformed into an open die that has a forming
surface.
• The shockwave forces the blank into engagement
with the forming surface to form the metal blank into
the desired shape.
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 Electro Hydraulic Forming (EHF)
Constructional Details and Working
• The deformation can be controlled by applying external restraints in the form of die or
by varying the amount of energy released,

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 Electro Hydraulic Forming (EHF)

Applications

▪ It include smaller radar dish, cone and other shapes in

thinner and small works,
▪ Reduction of capital investment for low volume aerospace applications,
▪ In Automobile sector such as inside components of a
passenger car door,
▪ Miniature and fancy equipment having complicated profile for electronic
industry, etc.

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Electrohydraulic
 Electrohydraulic

• Similar to Explosive
forming
• Discharges energy
between electrodes to
create shockwaves
• Used under water medium
to develop pressure
• Less energy than Explosive
 Electromagnetic Forming
▪ This process is based on the principle
stated by lorentz force law that the
electromagnetic field of an induced
current always opposes the
electromagnetic field of the inducing
current.
▪ In this method a large capacitor bank is
discharged producing a current charge
through a coiled conductor.

▪ The process is very rapid and is used

primarily to expand or contract tubing or to
permanently assemble component.

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