High Energy Rate Forming
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1 High Energy Rate Forming Large workpiece: Aircraft exhaust ducts and engine shrouds, Missile nose, Tank car bulkhead, Rocket fuel tank
2 High Energy Rate Forming (HERF) Main characteristic: Very high Forming velocity compared to conventional forming processes: Energy in HERF Very wide range depending upon job: 10 J-1x10 9 J
3 Methods of High Energy Rate Forming Process 1. Electromagnetic ( Magnetic) forming process 2. Explosive forming process 3. Electro-hydraulic forming process
4 1. Electromagnetic forming process Essential components: 1. Coil 2. Die 3. High current source 4. Workpiece (Electrically conductor / Conductive metal driver or coating for poor conductors) Process: Coil job & die kept at close proximity High pulse current passed through coil by discharging energy stored in capacitor Current in coil produces magnetic field Time varying magnetic field induces Eddy current in workpiece In turn, Eddy current in workpiece produces magnetic field which repels the coil magnetic field Equal and opposite force exerted on coil & workpiece Workpiece is pressed against die & formed Typical Pressure 345MPa at 130kA current
5 Electromagnetic forming process: Coils & Dies
6 Workpiece : High electrically conductive Poor conductive worpiece: formed with consumable driver plate / coating on the workpiece surface Advantages: Only one die No requirement for part lubrication Easily automated with high rates Applicable for high-volume production Disadvantages: Coil replacement sometimes limits configuration High capital cost Limited size and thickness of jobs Potential safety hazard
7 2. Explosive Forming: Shock wave generated by detonating explosive produces several MPa pressure on workpiece System: Standoff operation: 1) An explosive charge 2) An energy transmitting medium 3) A die assembly 4) Workpiece. Process: Mounting & securing of Blank on Die Placing the assembly in a water tank Placing required amount of explosive at a suitable stand-off distance Evacuating the die Detonating charge Removing workpiece from die after explosive forming
8 Two types of Explosive Forming: Low explosive: Explosive gas and gun cartridges Workpiece and die : complete confinement Confinement maximizes pressure Pressure: Typical 700MPa Forming time : Millisecond Confined HERF operation using a combustible gas mixture as energy source (Source: Bickert and Zeigler, 1977)
9 Confined HERF operation using a low-explosive cartridge-type energy source (Source: Begeman and Amstead, 1969)
10 High Explosive: TNT, Primacord, RDX Large size workpiece Very intense Shock wave no need of confinement Forming in 100 s microsecond time Pressure 10,000 s MPa Energy transfer media: Air, Water (common) Forming time : 100 Microsecond
11 High Explosive Forming: Peak Pressure Generated in water p = K[W 1/3 /R] a Where p = peak pressure in psi, K= constant, depends on type of explosive (e.g for TNT), W= Weight of Explosive in pounds, R = Distance of explosive from workpiece in feet, a= constant ~ 1.15
12 High Explosive: Workpiece: Plate or Cylindrical Advantages of Explosive Forming: Forming large parts up to 6m diameter, Draw depth/ diameter =25:1 Maintains precise tolerances. Tolerance in part profile mm Eliminates costly weld, Reduced tooling time, Less expansive
13 3. Electro-hydraulic Forming Process Electro-shape / Electro-spark Forming Forming produced by the pressure imparted by the shock wave generated by electric spark Spark produced by discharging a capacitor bank in a thin bridge wire in water or directly in a water-gap. Voltage: 5-20kV Process similar to Explosive Forming except for chemical explosion Pressure of 1200 MPa produced with kj energy Preferred over Explosive Forming for relatively small components: Shorter cycle time & safe operation, Work-media: Water, Glycerin, light oil
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