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    HERF

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    Dhiraj Rauniyar
    Electro hydraulic forming uses electrical energy stored in capacitors to generate shock waves through a workpiece filled with water, deforming the workpiece. Explosive forming uses explosives to generate high pressure that forces metal into dies. There are two techniques - contact uses explosives in direct contact with metal, while standoff detonates explosives at a distance. The shock waves travel through water to deform the workpiece. Explosive forming has been used since the 1880s and was important for missile components. It can form complex shapes and is useful for low production runs of difficult parts.

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    HERF

    Uploaded by

    Dhiraj Rauniyar
    106 views9 pages
    Electro hydraulic forming uses electrical energy stored in capacitors to generate shock waves through a workpiece filled with water, deforming the workpiece. Explosive forming uses explosives to generate high pressure that forces metal into dies. There are two techniques - contact uses explosives in direct contact with metal, while standoff detonates explosives at a distance. The shock waves travel through water to deform the workpiece. Explosive forming has been used since the 1880s and was important for missile components. It can form complex shapes and is useful for low production runs of difficult parts.

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    HERF

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    Electro hydraulic forming uses electrical energy stored in capacitors to generate shock waves through a workpiece filled with water, deforming the workpiece. Explosive forming uses explosives to generate high pressure that forces metal into dies. There are two techniques - contact uses explosives in direct contact with metal, while standoff detonates explosives at a distance. The shock waves travel through water to deform the workpiece. Explosive forming has been used since the 1880s and was important for missile components. It can form complex shapes and is useful for low production runs of difficult parts.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    106 views9 pages

    HERF

    Uploaded by

    Dhiraj Rauniyar
    Electro hydraulic forming uses electrical energy stored in capacitors to generate shock waves through a workpiece filled with water, deforming the workpiece. Explosive forming uses explosives to generate high pressure that forces metal into dies. There are two techniques - contact uses explosives in direct contact with metal, while standoff detonates explosives at a distance. The shock waves travel through water to deform the workpiece. Explosive forming has been used since the 1880s and was important for missile components. It can form complex shapes and is useful for low production runs of difficult parts.

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    of 9

    short time to a bank of capacitors connected in parallel.

    (The amount of electrical


    energy stored in the bank can be increased either by adding capacitors to the bank or
    by increasing the voltage). 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.

    Electro Hydraulic Forming


    Electro hydraulic forming (EHF), also known as electro spark forming, is a process in
    which electrical energy is converted into mechanical energy for the forming of metallic
    parts. A bank of capacitors is first charged to a high voltage and then discharged across
    a gap between two electrodes, causing explosions inside the hollow work piece, which
    is filled with some suitable medium, generally water. 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.

    Explosive forming process


    Explosive forming, is distinguished from conventional forming in that the punch or
    diaphragm is replaced by an explosive charge. The explosives used are generally high
    explosive chemicals, gaseous mixtures, or propellants. There are two techniques of
    high explosive forming: stand off technique and the contact technique.
    1. Introduction and Overview

    Explosive Forming is a manufacturing technique that uses explosions to force metal into
    dies and molds. The explosives are typically either detonated underwater or in direct
    contact with the materials. The technique is useful for short production runs of
    conventionally difficult-to-manufacture parts.

    1.1 History of Explosive Forming


    Explosive forming was first documented in 1888. It was used in the engraving of
    iron plates. In this engraving, the explosive was placed in direct contact with metal,
    and the thickness of the explosive layer on the plate determined the depth of indention
    made after detonation.

    As early as the 1950s, aerospace companies in the United States, such as


    Rocketdyne, Aerojet General Corporation, and Ryan Aeronautical were using explosive
    forming for the manufacture of complex curved aerospace components. Explosive
    forming was especially important in the development of short-production-run missile
    componentsparticularly for the curved domes of missiles and rocket nose cones.
    During this time, the Soviet Union also began using explosive forming in their
    rocket industries for large curved panels.
    1.2 Other forms of Explosive Metal Working
    There are numerous types of metalworking done with explosives. This paper will
    focus only on explosive forming. However, some other metal working techniques are:

    Explosive welding
    Explosive cutting
    Explosive powder forming
    Explosive sheet lamination
    Explosive coating
    Explosive stress relieving
    Explosive compaction
    Explosive cleaning

    1.3 Types of Explosive Forming


    Explosive forming can be separated into two different categories: contact
    operations and standoff operations.

    Contact operations place the explosive in direct contact with the metal.
    Standoff operations places the explosive charge some distance away from the
    workpiece.

    [a] Standoff Technique


    The sheet metal work piece blank is clamped over a die and the assembly is lowered
    into a tank filled with water. The air in the die is pumped out. The explosive charge is
    placed at some predetermined distance from the work piece, see Fig 1.1. On detonation
    of the explosive, a pressure pulse 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.
    Fig 1.1 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) workpiece is deformed, and (iv) gas bubbles vent
    at the surface of water.
    The system used for Standoff Method consists of following parts: -

    1) An explosive charge
    2) An energy transmitted medium
    3) A die assembly
    4) The work piece

    The die assembly is put together on the bottom of a tank. Workpiece is placed on the die and
    blankholder placed above. A vacuum is then created in the die cavity. The explosive charge is
    placed in position over the centre of the workpiece. The explosive charge is suspended over the
    blank at a predetermined distance. The complete assembly is immersed in a tank of water.

    After the detonation of explosive, a pressure pulse of high intensity is produced. A gas bubble is
    also produced which expands spherically and then collapses until it vents at the surface of the
    water. When the pressure pulse impinges against the workpiece, the metal is displaced into the
    die cavity.

    a.1Transmission Medium
    Energy released by the explosive is transmitted through medium like air, water, oil, gelatin,
    liquid salts. Water is one of the best media for explosive forming since it is available readily,
    inexpensive and produces excellent results. The transmission medium is important regarding
    pressure magnitude at the workpiece. Water is more desirable medium than air for producing
    high peak pressures to the workpiece.

    The use of water as the energy transfer medium ensures a uniform transmission of
    energy and muffles the sound of the explosive blast.

    Explosive forming

    The peak pressure generated in water is given by the expression

    p = peak pressure

    K = constant for type of explosive

    W = weight of the explosive

    R = distance of explosive from workpiece

    a = constant
    [b] Contact Technique
    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 (upto 30,000MPa) on the surface of the work piece resulting in metal
    deformation, and possible fracture. The process is used often for bulging tubes, as
    shown in Fig 1.2

    Fig 1.2 Schematic illustration of contact technique of explosive forming

    2. Explosives

    Explosives are substances that undergo rapid chemical reaction during which heat and large
    quantities of gaseous products are evolved. Explosives can be solid (TNT-trinitro toluene), liquid
    (Nitroglycerine), or Gaseous (oxygen and acetylene mixtures). Explosives are divide into two
    classes; Low Explosives in which the ammunition burns rapidly rather than exploding, hence
    pressure build up is not large, and High Explosive which have a high rate of reaction with a large
    pressure build up. Low explosives are generally used as propellants in guns and in rockets for the
    propelling of missiles.

    Property High Explosives Low Explosives


    Method of
    Primary HE-ignition, spark, flame, or impact Ignition
    initiation
    Secondary HE-detonator, or detonator and
    booster combination
    Conversion
    Microseconds Milliseconds
    time+
    Pressure up to about 4,000,000psi up to about
    40,000psi

    + Time required to convert a working amount of high explosive into high-pressure gaseous products

    Fig: 2.1 Three general methods for explosive forming using high explosives

    3. Die Materials
    Different materials are used for the manufacture of dies for explosive working, for instance high
    strength tool steels, plastics, concrete. Relatively low strength dies are used for short run items
    and for parts where close tolerances are not critical, while for longer runs higher strength die
    materials are required. Kirksite and plastic faced dies are employed for light forming operations;
    tool steels, cast steels, and ductile iron for medium requirements.

    Material of Die Application Area

    Kirksite Low pressure and few parts


    Fiberglass and Kirksite Low pressure and few parts
    Fiberglass and Concrete Low pressure and large parts
    Epoxy and Concrete Low pressure and large parts
    Ductile Iron High pressure and many parts
    Concrete Medium pressure and large parts

    The process is versatile a large variety of shapes can be formed, there is virtually no
    limit to the size of the work piece, and it is suitable for low quantity production as well.

    4. Characteristics of Explosive Forming Process


    Very large sheets with relatively complex shapes, although usually axisymmetric.
    Low tooling costs, but high labor cost.
    Suitable for low-quantity production.
    Long cycle times.

    5. Formability Aspects

    Formability has been defined as the ability of a sheet metal to be deformed by a specific sheet
    metal forming process from its original shape to a defined shape without failure. In normal
    explosive forming operations, the major characteristics of the work metal that determine
    formability are ductility and toughness. It is general practice not to exceed the elongation, as
    determined by the tension testing, in forming a part from the same metal. Following table shows
    the comparison of the formability of some metals, using annealed aluminium alloy 1100 as a
    basis.

    6. Advantages of Explosion Forming


    1. Maintains precise tolerances
    2. Eliminates costly welds.
    3. Controls smoothness of contours.
    4. Reduces tooling costs.
    5. Less expensive alternative to super-plastic forming.
    References
    [1] Rinehart J.S and Pearson, John, Explosive Working of Metals, Pergamon Press,
    1963. New York.

    [2] EXPLOSIVE FORMING - An Overview, by AmitMukund Joshi, Junior Research


    Fellow at Indian Institute of Technology, Bombay.

    [3] Ezra A.A, Principles and practices of explosive metal working.

    [4]Metals Handbook, ASM.

    [5]Manufacturing processes for Engineering Materials, 4/e

    By Kalpak Jain

    [6]Tool materials By Joseph R. Davis

    [7] Devices for the explosive forming of workpieces, US Patent 3600921

    [8] Tank for explosive forming, US Patent 4174624

    Resources
    1. (http://www.metalwebnews.com/howto/explosive-forming/explosive-forming.html)
    2. TNO PML Website, "Explosive Forming for the Aerospace market"
    (http://www.pml.tno.nl/en/products_services/emb/explosive_forming_technology_ae
    rospace.html) Accessed 4/06/13.
    3. Exploform Company Website. (http://www.exploform.com/old/Zindex2.htm)
    Accessed 4/06/13.

    4. http://www.exploform.com/old/produktie.htm

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