INDIAN INSTITUTE OF TECHNOLOGY, BHU

ELECTRO HYDRO FORMING

SUBMITTED TO: Dr. RAJNESH TYAGI

Department of Mechanical Engineering, IIT BHU

SUBMITTED BY: SOURABH KUMAR

Roll no.- 19132049
M.Tech (Prod. Technology)
INTRODUCTION 12-Nov-19

• This process is known as Electro Discharge Forming.

• In this forming process, large amount of energy is applied in a short
interval of time
• The parts are formed at a rapid rate, thus this process is also known as
High Velocity Forming (HVF) process
• There are several advantages of using this forming process, like
 Die costs are low
 Easy maintenance of tolerances
 Possibility of forming most metals
 Materials do not show springback effect
• The production cost of components by this process is very low.
• The limitation of this process is the need for the skilled labour

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PROCESS PRINCIPLE 12-Nov-19

• A high pulse current coming from a high voltage

generator (Capacitor) is discharged through an
arc between two electrodes located in water.
• The energy deposition is made through Joule
heating of the plasma, creating a rapid bubble
expansion, and therefore a shock wave is
generated.
• This shock wave propagates in the water towards
the blank and causes the plastic deformation of
the workpiece against the die.

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Constructional Details
• A typical configuration of EHF includes a
discharge chamber, electrodes, forming dies and
a capacitor
• 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 at top of the
discharge chamber.
• An one sided die is placed over the blank.
• After the air is evacuated from both sides of the
blank, the chamber is filled with water with
completely immersed electrodes.

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Working 12-Nov-19

• After the voltage is applied to the electrodes, an

electrical breakdown occurs between the exposed
tips of the electrodes
• Consequently the plasma 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
• 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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Advantages
• A single-step process (rather than progressive stamping)
• EHF can form hollow shapes with much ease and at less cost compared to
other forming techniques
• Fine details and sharp lines can be easily formed
• Forming of male and female shapes (negative and positive)
• Only a single one-sided die is required
• Extremely fast
• Enables extremely deep forming (much more than is possible with
conventional stamping)
• The process does not depend on the electrical properties of the work material
• Safer in handling than the explosive materials.

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Disadvantages
• Suitable only for smaller works.
• Need for vacuum makes the equipment more complicated.
• 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

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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 equipments having complicated profile
for electronic industry etc.

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References
1. Dr. Dipl.Ing. Elisa Cantergiani, Dr. Dipl.Ing. Gilles Avrillaud
“Example of two industrial Electro-Hydraulic Forming applications
highlighting the advantages of high strain rates
2. https://www.sciencedirect.com/science/article/pii/S2351978918311028
3. https://www.researchgate.net/publication

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THANK YOU

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