1 Electro-Hydraulic Forming Process

Chapter 1

INTRODUCTION
1.1 Rate of Strain and Forming Processes The forming processes are affected by the rates of strain used. Effects of strain rate during forming [3]: The flow stress increases with strain rates The temperature of work is increases due to adiabatic heating. Improved lubrication if lubricating film is maintained. Many difficult to form materials like Titanium and Tungsten alloys, can be deformed under high strain rates. But, Low strain-rate leads to, Necking in a small area Little plastic deformation in bulk and localized thinning leads to fracture. 1.2 High Energy Rate Forming (HERF) Hurdles with the strain rate and after effects lead to the evolution of High Energy Rate Forming (HERF). Features of HERF processes: The energy of deformation is delivered at a much higher rate than in conventional practice. Larger energy is applied for a very short interval of time. The velocity of deformation is also very large and hence these are also called High Velocity Forming (HVF) processes. Many metals tend to deform more readily under extra fast application of force. Large parts can be easily formed by this technique. For many metals, the elongation to fracture increases with strain rate beyond the usual metal working range, until a critical strain rate is achieved, where the ductility drops sharply. High rates of strain cause the yield point to appear in tests on low carbon steel that do not show a yield point under ordinary rates of strain. HERF includes Electro-hydraulic, Electromagnetic, Explosive and pneumatic mechanical processes.

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2 Electro-Hydraulic Forming Process

Chapter 2

ELECTRO-HYDRAULIC FORMING (EHF)

2.1 Principle Electro-Hydraulic Forming is a type of metal forming in which an electric arc discharge in liquid (Yutkin effect) is used to convert electrical energy to mechanical energy and change the shape of the work piece. A capacitor bank delivers a pulse of high current across two electrodes, which are positioned a short distance apart while submerged in a fluid (water or oil). The electric arc discharge rapidly vaporizes the surrounding fluid creating a shock wave. The work piece, which is kept in contact with the fluid, is deformed into an evacuated die. The potential forming capabilities of submerged arc discharge processes were recognized as early as the mid 1940s (by Yutkin L.A.). In 1950,this work principally was by and for the aerospace industries. By 1970, forming machines based on submerged arc discharge, were available from machine tool builders. A few of the larger aerospace fabricators built machines of their own design to meet specific part fabrication requirements. Electro-hydraulic forming is a variation of the older, Explosive Forming method. The only fundamental difference between these two techniques is the energy source, and subsequently, the practical size of the forming event.

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3 Electro-Hydraulic Forming Process

2.2 Construction and Working The constructional features of the EHF system can be observed in schematic representation Fig.1

Fig.1. Schematic representation of EHF process system A bank of capacitors is first charged to a high voltage and then discharged across a gap between two electrodes (or the spark initiation wire), causing explosions inside the hollow work piece, which is filled with some suitable medium. These explosions produce shock waves that travel radially in all directions at high velocity until they meet some obstruction. If the discharge energy is sufficiently high, the hollow work piece is deformed. The deformation can be controlled by applying external restraints in the form of die or by varying the amount of energy released The energy needed for the forming process is stored in a set of charged capacitors. The rapid switching device is closed, leading to a rapid discharge between the electrodes inside a chamber filled with water. A pressure wave is thus produced, and water is forced against the sheet to be formed, based on the design of the chamber. Depending on the material and shapes to be formed, one or several discharges are needed. The total number of discharges is also dependent on the energy used in the forming stages The machine is equipped with an automated control system, which makes it possible to set in advance the number of discharges. The mean time between discharges is around

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4 Electro-Hydraulic Forming Process

five seconds. No noticeable increase in temperature on the surface of the formed sheet is observed. Also the recent researches have shown that use of reflectors has brought drastic increase in the process efficiency. 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, etc. 2.3 Process Characteristics 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. Material properties with regard to the application of high rates of strain. 2.4 Electrical Process Parameters The discharge voltage is the major parameter that has substantial effect on displacement or the material deformation [4]. The researches have revealed that increasing voltage has linear relationship with deformation of work material and finite element analysis of the process is illustrated in Fig.2

Fig.2. FEM illustration of Voltage versus displacement However, there are several other electrical parameters to be maintained in the process and are, Maximum capacitance 60 f (10 x 6 f)

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5 Electro-Hydraulic Forming Process

Maximum charging voltage 40 kV Maximum impulse energy 48 kJ Impulse frequency 0.2 Hz A maximum current up to 200 ka can be achieved The maximum input power required is 25 kW 2.5 Advantages Better control of the pressure pulse as source of energy is electrical- which can be easily controlled. Safer in handling than the explosive materials. More suitable if the work size is small to medium. Minimal spring back of formed sheets (IT9) Thin plates can be formed with smaller amounts of energy. EHF is more adaptable to automatic production The process does not depend on the electrical properties of the work material. 2.6 Limitations Suitable only for smaller works. Need for vacuum. Need for proper SOD. Materials having low ductility or having critical impact velocity less than 30 ms-1 are generally not considered to be good candidate for EHF. Above 5 mm thick plate not give good results in EHF.

2.7 Applications Manufacturing of smaller radar dish, cone and other shapes in thinner and small works, Bulged thin tubes/ pipes, Crimps on metal strips, etc.,

Fig.3. Products produced by HEF process

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References 1. Metal forming processes Sadhu singh 2. NPTEL-IIT Roorkee Lecture on High Rate Energy Forming 3. K. Osakada-Effects of Strain Rate and Temperature in Forming Processes of Metals, PHYS IY FRANCE 7 (1 997) Colloque C3, Suppltment au Journal de Physique 111 d'aoiit 1997 4. Aashish Rohatgi et.al., Experimental characterization of sheet metal deformation during electro-hydraulic forming, ournal of Materials Processing Technology 211 (2011) 1824 1833 5. W. Homberg et.al., Investigation of the electrohydraulic forming process with respect to the design of sharp edged contours, Chair Of Manufacturing And Forming Technology (Luf), Paderborn University, paderborn germany

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