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Fdocuments - in Unconventional Metal Forming Process

The document discusses three main high energy rate forming processes: explosive forming, magnetic forming, and electro hydraulic forming. These processes use large amounts of energy applied very quickly to deform metals. They allow for forming of large or difficult to form parts at high speeds. Some advantages are low die costs, easy maintenance of tolerances, ability to form most metals, and reduced springback. Explosive forming uses explosives, magnetic forming uses electromagnetic pulses, and electro hydraulic forming uses electrical discharges under water to rapidly deform hollow workpieces. These processes find applications in aerospace and automotive industries for prototype and large part formation.

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112 views

Fdocuments - in Unconventional Metal Forming Process

The document discusses three main high energy rate forming processes: explosive forming, magnetic forming, and electro hydraulic forming. These processes use large amounts of energy applied very quickly to deform metals. They allow for forming of large or difficult to form parts at high speeds. Some advantages are low die costs, easy maintenance of tolerances, ability to form most metals, and reduced springback. Explosive forming uses explosives, magnetic forming uses electromagnetic pulses, and electro hydraulic forming uses electrical discharges under water to rapidly deform hollow workpieces. These processes find applications in aerospace and automotive industries for prototype and large part formation.

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Fuzzy is Easy
Copyright
© © All Rights Reserved
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Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 12

UNCONVENTIONAL METAL

FORMING PROCESSES

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High Energy Rate Forming Processes

 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 to form large size parts out of most metals
including those which are otherwise difficult – to
form.        

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 The parts are formed at a rapid rate, and thus these processes
are also called high – velocity forming processes.
 There are several advantages of using these forming processes,
like die costs are low, easy maintenance of tolerances,
possibility of forming most metals, and material does not show
spring-back effect.
 The production cost of components by such processes is low.
The limitation of these processes is the need for skilled
personnel.

3
Classification

There are three main high energy rate forming processes:

 Explosive Forming
 Magnetic Forming, And
 Electro Hydraulic Forming

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Explosive Forming
 Explosive forming, is distinguished from conventional
forming in that the punch or diaphragm is replaced by an
explosive charge. T
 he 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.

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Applications

 Explosive forming is mainly used in the aerospace


industries but has also found successful applications in
the production of automotive related components.
 The process has the greatest potential 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
 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.

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Continued…

Magnetic forming can be accomplished in any of the


following three ways, depending upon the requirements.

 Coil surrounding work piece.


 Coil inside work piece.
 Coil on flat surface

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Applications
 Electromagnetic forming process is capable of a wide variety of
forming and assembly operations.
 It has found extensive applications in the fabrication of hollow,
non – circular, or asymmetrical shapes from tubular stock.
 The compression applications involve swaging to produce
compression, tensile, and torque joints or sealed pressure joints,
and swaging to apply compression bands or shrink rings for
fastening components together.
 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 riveting.
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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.
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Advantages

 EHF can form hollow shapes with much ease and at less
cost compared to other forming techniques.
 EHF is more adaptable to automatic production
compared to other high energy rate forming techniques.
 EHF can produce small – to intermediate sized parts that
don't have excessive energy requirements.

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