SPECIAL FORMING

TECHNIQUES
ARPIT GARG | KURJA RATHORE |NAVNEET SINGH |
KIRAN JANGIR |
TUSHAR MANI AGARWAL | JUHI AGARWAL | RAHUL
SHARMA |
KHUSHBOO AGARWAL | SHIKHER GUPTA |
 SPECIAL FORMING TECHNIQUES

UNCONVENTIONAL
PROCESSES

HERF HVF
(HIGH ENERGY RATE
(HIGH VELOCITY FORMING)
FORMING)
 HERF
(HIGH ENERGY RATE FORMING)

EMF EHF
EXPLOSIVE
(ELECTRO (ELECTRO
FORGING
MAGNETIC HYDRAULIC
FORMING) FORMING)

LINEAR
CONTACT STAND OFF
PNEUMATIC PETROFORGE INDUCTION
OPERATION OPERATION
MOTOR

EXPANSION COIL COUNTER FORMING COMPRESSION COIL

FORMING PROCESS PROCESS
 HIGH ENERGY RATE FORMING
PROCESS [HERF ]

It is a process that form products at very high velocities and

extremely high pressure
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.

These processes are useful to deform materials like Titanium and Tungsten alloys,
under high strain rates.
EXPLOSIVE FORMING
In Explosive Forming a punch in conventional forming is replaced by
an explosive charge.

Explosives used can be: High explosive chemicals like TNT, RDX, and
Dynamite, Gaseous mixtures & Propellants.

There are two techniques of high - explosive forming:

Stand - off technique or Unconfined Type

Contact technique or Confined Type

 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.
 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.
 ROLE OF WATER

 Acts as energy transfer medium

 Ensures uniform transmission of energy
 Muffles the sound of explosion
 Cushioning/ smooth application of energy on the work without direct contact.

PROCESS VARIABLES

 Type and amount of explosive: wide range of explosives are available.

PROCESS VARIABLES (continued)

 Standoff distance :
SOD- (Distance between work piece and explosive): Optimum SOD must be
maintained.
 The medium used to transmit energy: water is most widely used.
 Work size
 Work material properties
 Vacuum in the die
 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
 DISADVANTAGES

 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.
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.

ELECTRO MAGNETIC FORMING OR MAGNETIC PULSE
FORMING
 In this method the electrical energy stored in a capacitor bank is used to produce opposing
magnetic fields around a tubular work piece, surrounded by current carrying coils. The coil is
firmly held and hence the work piece collapses into the die cavity due to magnetic repelling
force, thus assuming die shape.
 The process is also called magnetic pulse forming and is mainly used for swaging type
operations, such as fastening fittings on the ends of tubes and crimping terminal ends of cables.
 Other applications are blanking, forming, embossing, and drawing.
 The work coils needed for different applications vary although the same power source may
be used.
 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
 CONSTRUCTIONAL DETAILS & WORKING

• The setup of EMF consists of the pulsed power generator, the inductor including a
fieldshaper, if applicable, the workpiece and application dependent further tool components
such as form-defining dies etc.
• The process is started by charging and subsequently discharging the capacitor of the pulsed
power generator.
• A sinusoidal current flows through the inductor. This current induces a corresponding
magnetic field.
• If there is an electrically conductive workpiece in direct proximity to inductor, a second
opposedly directed current is induced.
• The energy density stored in the magnetic field between workpiece and inductor acts as
magnetic pressure which can reach several hundreds of megapascal and causes the
acceleration and deformation of the workpiece.
• The direction of the movement is always targeted away from the inductor
 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,
(ii) electromagnetic sheet forming, for which an inductor is positioned in close
proximity of a flat semi-finished part or a preformed component.

(iii) electromagnetic expansion of tubes and hollow profiles by means of an inductor

positioned within the workpiece
 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.
 PROCESS VARIANTS

 Workpiece thickness – Ahigher thickness means that the magnetic field diffuses slower through
the workpiece wall.
 Electrical conductivity – The higher the electrical conductivity of the workpiece, the better the
shielding of the magnetic field, the pressure difference in higher.
 Frequency – A higher frequency of the discharged current can balance a low conductivity or a
small wall thickness.
 Size of the capacitor bank
 The strength of the current, which decides the strength of the magnetic field and the force
applied.
 Gap between workpiece and tool coil – The smaller the air gap, higher is magnetic field and
pressure.
 Winding of the tool coil – For each pulse generator and each forming task exists an optimum of
number of turns.
 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
 APPLICATIONS

 Electromagnetic forming process is capable of a wide variety of forming and assembly operations.
 Crimping of coils, tubes, wires
 Bending of tubes into complex shapes
 Bulging of thin tubes.
 It has found extensive applications in the fabrication of hollow, non – circular, or asymmetrical
shapes from tubular stock.
 Flat coils have been used on flat sheets to produce stretch (internal) and shrink (external) flanges
on ring and disc – shaped work pieces.
 Electromagnetic forming has also been used to perform shearing, piercing, and rivettting.
 Hydroforming

• This process is also called hydromechanical forming, hydraulic forming or

hydropunch forming.
• Hydroforming is a metal fabricating and forming process which allows the
shaping of metals such as steel, stainless steel, copper, aluminum, and brass.
• This process is a cost-effective and specialized type of die molding that utilizes
highly pressurized fluid as a medium of energy transfer to form metal.
• Generally 2 types, sheet hydroforming and tube hydroforming.
 Sheet hydroforming
 Sheet hydroforming process is an alternative to drawing process where either punch or die is
replaced by hydraulic medium, which generates the pressure and forms the part.
 Sheet hydroforming
 Sheet hydroforming is classified into two types Sheet Hydroforming with Punch (SHF-P) and Sheet
Hydroforming with Die (SHF-D).
 In SHF-P (Figure 2(a)), the hydraulic fluid is replaced with the die, while in SHF-D (Figure 2(b)), the hydraulic
fluid is replaced with the punch. Absence of either punch or die in SHF process reduces the tooling cost
 Tube Hydroforming

• Tube HydroForming (THF) is a process of forming hollow parts with

different cross sections
• by applying simultaneously an internal hydraulic pressure and axial
compressive loads to
• force a tubular blank to conform to the shape of a given die. Geometry
of die and workpiece
Tube Hydroforming
 Advantages
 Part consolidation
 Weight reduction through more efficient section design
 Improved structural strength and stiffness
 Lower tooling cost due to fewer parts
 Fewer secondary operations (no welding of sections required and holes may be pierced during
hydroforming)
 Tight dimensional tolerances.

Limitations
 Despite several benefits over stamping process, THF technology is still not fully implemented in the
automotive industry due to its time-consuming part and process development .
Tube Hydroforming
 Advantages
 Superior Surface Quality
 Because the sheet of metal being pressed never comes into contact with actual tooling equipment,
the chances of structural and surface damage are drastically reduced.
 Abrupt changes in stress are avoided – a factor that ensures high dimensional accuracy and
reduces the tendency of the material to return to its original size and shape when the applied load is
removed.
 Shock lines, draw marks, wrinkling, and tearing associated with matched die forming are
eliminated.
 Tight dimensional tolerances and low springback
 Lightweight Items
 exhibit superior strength to weight ratio.
 complex shapes can be created with uniform wall thicknesses
 Advantages
 Versatility of Materials
 This process allows for the use of any ductile metals to be hydroformed
 The thickness of the sheets to be formed can range anywhere from 0.05 mm
to 6mm.
 Manufacturing Savings
 not require the use of guide way systems or hold-down device,  generates very little waste from
the process
 tooling costs are cut in half due to only needing the negative molding tool
 The result is reduction in manufacturing time and production costs.
 Additionally, complex shapes can often be created using one machine, which negates the necessity
for more machinery to be running.
 Inexpensive tooling costs and reduced set-up time.
 Reduced development costs as no new prototype is needed
 Materials and blank thickness specifications can be optimized to achieve cost savings.
 Disadvantages

• Slow cycle time.

• Expensive equipment.

• Lack of extensive knowledge base for process and tool design.

 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.

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.
 Construction and working
• A typical configuration of EHF includes a discharge chamber, electrodes, forming die, and a pulse
generator which consists of a high-voltage low inductive bank of capacitors C, a high-voltage/high
current discharge switch D, and a charging/amplifying/rectifying circuit is illustrated in Fig 1.
• The capacitor bank is capable of producing discharges of 5–25 kV and can store energies up to 100
kJ.
• A sheet metal blank is placed on top of the discharge chamber.
• A one-sided die is positioned above the blank.
• After the air is evacuated from both sides of the blank, the chamber is filled with water, fully
immersing the electrodes.
• After the voltage is applied to the electrodes, an electrical breakdown occurs between the exposed
tips of the electrodes which leads to the formation of a stable plasma channel.
• The channel expands quickly resulting in shock waves of pressure which then continuously
transform into flow of liquid. The pressure pulse propagates through the water and applies pressure to
the surface of the blank forming it into the die cavity
Construction and working
 Construction and working
• The deformation can be controlled by applying external restraints in the form of die or by varying the amount of
energy released,
 Process parameters
• Stand off distance : It must be optimum.
• Capacitor used : The energy of the pressure pulse depends on the size of capacitor.
• Transfer medium : Usually water is used.
• Vacuum : The die cavity must be evacuated to prevent adiabatic heating of the
work due to a sudden compression of air.
• Materials formed : Materials having low ductility or having critical impact
velocity less than 30 m/s are generally not considered to be good candidate for EHF.
All materials that can be formed by conventional forming processes can be formed
by EHF also. These materials are aluminum alloys, nickel alloys, stainless steels,
titanium, and Inconel 718.
 Advantages
 EHF can form hollow shapes with much ease and at less cost compared to other
forming techniques.
 A single step process (rather than progressive stamping)
 Extremely fast
 Enables extremely deep forming (much more than is possible with conventional
stamping)
 Fine details and sharp lines can be easily formed
 Forming of male and female shapes (negative and positive)
 The process does not depend on the electrical
 properties of the work material.
 Safer in handling than the explosive materials.
 Disadvantages
 Suitable only for smaller works.
 Need for vacuum makes the equipment more complicated.
 Proper SOD is necessary for effective process.
 Each discharge of the electrodes to create the high voltage discharge in the fluid
results in the formation of impurities in the water that results in vaporization of the
electrodes and may create surface defects in the surface of the part formed in the
process.
 The fluid in the vessel generally must be drained and replaced for each tool cycle.
The volume of fluid in the vessel for a larger part tends to be fairly substantial and a
considerable portion of the cycle time of the tool is dedicated to draining and
refilling the vessel
 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.
ADVANTAGES
 Die costs are low
 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.