Manufacturing Technology High Velocity Forming

I.
Rajkumar
Assistant professor I
KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
Anand Nagar, Krishnankoil 626 190
DEPARTMENT OF MECHANICAL ENGINEERING
SHEET METAL FORMING

Sheet metal forming is a process that materials
undergo permanent deformation by cold
forming to produce a variety of complex three
dimensional shapes.
kalasalingam university
i.rajkumar@klu.ac.in
HIGH VELOCITY FORMING
High velocity forming processes began to make

their mark and grow in application in 1960.
Requirements such as the introduction of super

tough alloys for space vehicles., supersonic aircraft
and the need for shaping incredibly small, thin and
brittle materials for electronic components helped
in the growth of high velocity forming processes.
In high velocity forming of metals, the metal is

shaped in micro-seconds with pressures generated
by the sudden application of large amounts of
energy.
HIGH VELOCITY FORMING

Pressures needed for forming are
generated by :
1.
Detonating explosives.
2.
Releasing compressed gases.
3.
Discharging powerful electrical sparks or
4.
Electromagnetic energy.
TYPES OF HIGH VELOCITY

FORMING PROCESSES
Explosive forming
Electro-hydraulic forming.
Magnetic forming
Pneumatic- mechanical high velocity forging..
EXPLOSIVE
FORMING
EXPLOSIVE FORMING
Explosive forming has evolved as one of the most dramatic

of the new metalworking techniques. Explosive forming is
employed in Aerospace and aircraft industries and has been
successfully employed in the production of automotiverelated components. Explosive Forming can be utilized to
form a wide variety of metals, from Aluminium to high
strength alloys
EXPLOSIVE FORMING
In this process the punch is replaced by an explosive charge.

The process derives its name from the fact that the energy
liberated due to the detonation of an explosive is used to form
the desired configuration. The charge used is very small, but
is capable of exerting tremendous forces on the work piece.
In Explosive Forming chemical energy from the explosives is

used to generate shock waves through a medium (mostly
water), which are directed to deform the work piece at very
high velocities.
Methods of Explosive
Forming
Explosive forming makes use of the pressure wave
generated by an explosion in a fluid to force the
material being formed against the walls of the
female die. The fluid has the effect of rounding off
the pressure pulse generated by the detonation.
Methods of Explosive Forming
The explosives are used in many forms- rod, sheet,

granules, liquid, stick etc. Depending upon the placement
of the explosive (charge), the operations fall into two
categories :
Stand-off operations.
Contact operations.
10
METHODS OF
EXPLOSIVE FORMING
Standoff Method
In this method, the explosive charge is located at some
predetermined distance from the work piece and the energy is
transmitted through an intervening medium like air, oil, or
water. Peak pressure at the work piece may range from a few
thousand psi to several hundred thousand psi depending on
the parameters of the operation.
11
METHODS OF EXPLOSIVE
FORMING
Contact
Method
In this method, the explosive charge is held in

direct contact with the work piece while the
detonation is initiated. The detonation produces
interface pressures on the surface of the metal up to
several million psi (35000 MPa).
12
WORKING PRINCIPLE
The system used for Standoff

operation consists of following
parts: 1) An explosive charge
2) An energy transmitted
medium
3) A die assembly
4) The work piece.
13
WORKING PRINCIPLE
-
Figure 1 shows an arrangement of Standoff Explosive
forming operation. The die assembly is put together on the

bottom of the tank. Work piece is placed on the die and blank
holder placed above. A vacuum is then created in the die cavity.
The explosive charge is placed in position over the centre of the
work piece. 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 work piece, the metal is displaced into the die cavity
14
EXPLOSIVES
Explosives are substances that undergo rapid chemical
reaction during which heat and large quantities of gaseous
products are evolved.
Explosives are divide into two classes;
-
Low Explosives in which the ammunition burns rapidly rather

than exploding, hence pressure build up is not large.
High Explosive which have a high rate of reaction with a large

pressure build up.
15
EXPLOSIVES
Various explosives used are:
Solid (TNT-trinitro toluene)
Liquid (Nitroglycerine)
Gaseous (oxygen and acetylene mixtures).
16
Advantages of Explosive Forming

Over Conventional forming
Low capital investment is required to adapt the process to

production.
Large and expensive presses are not needed for forming.
Component is generally formed in one shot only.
Only one die either male or female is needed. For this reason
tooling costs are greatly reduced.
In general terms, the ultimate strength and yield strength are

improved by high explosive forming.
Large size parts unable to be handled successfully by

conventional presses can be formed easily.
17
Disadvantages of Explosive
Forming Over Conventional
Personnel must forming
be highly trained in the safe
handling of high explosives.
The technique has not been developed to the

stage where a part can always be formed on the
first shot.
The noise developed during forming and the

strict laws prohibiting the use of high explosives
in populated areas, usually make it necessary to
locate the facility away from populated areas.
This increase transportation and handling costs.
18
Uses
Blanking
compacting
Cutting
Expanding
Coining
Powder
Embossing
Flanging
Drawing
Sizing etc.
Applications
Aerospace components.
19
ELECTRO
HYDRAULIC
FORMING (EHF)
20
INTRODUCTION
The ability to generate high intensity shock waves by discharging stored

electrical energy across electrodes submerged in a liquid medium has been
recognized for a great many years.
Spark discharge in a liquid was pointed out as a potential source of power

in 1944.
Basic research on under water condenser discharges was the subject of

several investigations in the early 1950s.
The first attempts to use electro hydraulic forming ( also called capacitor
discharge forming or spark forming ) process for forming metals were in
the United States in 1953 to punch holes in 1.5 mm steel plates.
21
PRINCIPLE OF OPERATION
22
Electro hydraulic forming involves the conversion of

electrical energy to mechanical energy in a liquid medium.
Discharging of an electric spark in a liquid produces shock
waves and pressures which can be used for metal forming.
As the energy produced is less than that produced in
explosive forming, it is usually necessary to repeat the
operation several times to achieve the desired results
23
METHODS TO CONVERT ELECTRICAL

ENERGY INTO MECHANICAL ENERGY
Capacitor discharge through a gap : Voltages of

10,000 to 30,000 volts are generally used when the
spark discharge method is utilized. This potential
difference will jump the air gap present between two
electrodes, submerged in the liquid.
24
METHODS TO CONVERT ELECTRICAL ENERGY

INTO MECHANICAL ENERGY
Capacitor discharge through a wire : provides better control than the

previous method because the path of the electrical discharge can be
positively determined and shaped, also a more efficient energy conversion
results. Moreover, with wire method, the use of lower potential difference is
possible; the wire will initiate a path across a wider gap than a specified
voltage will jump without the wire. A disadvantage of the wire method,
however, is that a new wire is to be loaded after each shot for parts requiring
multiple shots for reaching the desired results.
25
In electrohydrauylic forming, electrical energy replaces the explosive used

in explosive forming. High voltage electrical energy is discharged from a
capacitor bank (a device used to store electrical energy) into a thin wire or
foil suspended between two electrodes. The unit is immersed in water. As
the water vaporizes, the vapour products expand converting the electrical
energy to hydraulic energy. The shock wave forms (or shapes) the metal
against the die.
Since the energy produced for forming is less than that associated with
explosives, it is usually necessary to repeat the operations several times to
achieve the desired results
26
ADVANTAGES OF EHF OVER

CONVENTIONAL
FORMING:
Many designs requiring standard operations have some

peculiarity which is not within the capability of conventional
equipment, at least not without some special provision or
tooling. Such works can be easily undertaking by EHF.
When EHF is used, the cost of tooling will almost always be less
than that for conventional equipment.
Large amounts of energy can be directed into isolated areas as

required in some piercing operations.
Reproducibility is another main advantage.
27
DISADVANTAGES OF EHF
One of the most significant limitations of the process is the

energy rating of the capacitor bank itself, and the amount
of energy which can be dumped by the triggering device is
another.
Materials having critical impact velocities below 30 meters

per second are not practical for electohydraulic forming.
Neither is EHF of parts from materials having low ductility,

such as the titanium alloys, likely to be successful.
28
APPLICATIONS OF EHF:
A wide range of part sizes are producible by

EHF, and most materials can be worked.
The process is widely accepted in aerospace

industries to accomplish bulging , forming,
beading, drawing, blanking and piercing .
29
MAGNETIC PULSE
FORMING(MPF)
30
INTRODUCTION
One of the earliest developments in producing a short duration,

high intensity magnetic field was reported in 1924. A special
storage battery was used as the energy source.
Harvey and Brower, around 1958, demonstrated the application

of a magnetic system for forming metals.
In 1962, first magnetic commercial forming machine was

marketed
Using this technique, it is possible to apply to a metallic work

piece a powerful, uniform magnetic pulse to swage and expand
tubular forms, as well as to coin, shear and form flat sheets.
31
PRINCIPLE OF
OPERATION:
A basic magnetic pulse metal

forming circuit consists of
-An energy storage
capacitor,
-A switch
-A coil
-A power supply that
provides energy to charge a
capacitor
FIGURE : Schematic illustration of the magnetic-pulseforming process. The part is formed without physical
contact without physical contact with any object
32
PRINCIPLE OF
OPERATION:
An insulated induction coil is either
wrapped around, or placed within the

work, depending on whether the work
piece (metal) is required to be
squeezed inward or bulged outward.
The coil is shaped to produce the
desired shape in the work.
The power source is a capacitor bank.
Magnetic pulse forming machines

generate the very high currents
required to produce the magnetic
fields by discharging the capacitor
bank through the coil.
33
As a very high momentary currents are passed

through the coil an intense magnetic field is
developed that causes the work to collapse,
compress, shrink or expand depending upon the
designs and placement of the coil.
Energy storage capacity and ability of the unit to

utilize that energy determines the size of the work
that can be formed. Highly conductive metals can
be formed easily. Non conductive or low
conductivity materials can be formed if they are
wrapped or coated with a high conductivity
auxiliary material.
34
ADVANTAGES OF MPF OVER

CONVENTIONAL FORMING:
The pressure is applied to the work piece through the

medium of a magnetic field without any physical contact.
Since no static forces are involved in the process,

relatively high structures may be used for the support of
dies.
Since there is no friction between the magnetic field and

the work piece, no lubricants are required and the
process leaves no tool marks.
Machines can be designed for repetition rates of

hundreds of operations per minute.
35
LIMITATIONS OF MPF :
The configuration of the work piece must be such that

the area to be formed constitutes a closed loop, as in
the case of rings, tubes, circular areas on flat work
pieces etc., thus permitting the induced currents to
flow. Slits interrupting the paths of the induced
currents have a detrimental effect on MPF process.
It is not possible to apply high pressures in an

arbitrarily chosen area while applying a low pressure
in a closely adjacent area.
36
APPLICATIONS OF MPF :
The magnetic pulse forming process has been primarily applied in the
forming of excellent conductors, such as aluminum, copper, brass and
low carbon steel. It has also been used effectively to form poor
conductors such as stainless steel for use with highly conductive sheaths.
MPF is used widely to expand, compress or form tubular shapes and

has also been used effectively to form conical, ellipsoidal and flat work
pieces and assembly operations in a single step. The method is also used
for piercing, shearing, embossing, cupping, sizing, banding etc.
Tubular members can be joined to end fittings by magnetic swaging.
37
PNEUMATIC
MECHANICAL
HIGH VELOCITY
FORGING
38
COMPARASION WITH
CONVENTIONAL FORGING
Just as a turret lathe can be set up to machine hundreds of

identical parts, so also pneumatic mechanical, high velocity
forging machine can be set up to produce hundreds of
identical forging without depending on the skill of the
operator.
High velocity forging is a closed die hot or cold forging

process which unlike conventional forging, deforms work
metal at unusually high velocities. Identify, the final
configurations of the forging is developed in one blow, or at
most, in a few blows.
High velocity forging can be used for hot forging of the parts
of the same general shapes as those produced in conventional
forging hammers and presses.
39
COMPARASION WITH
CONVENTIONAL FORGING
The forces developed in high velocity forging are many

times more powerful and are sufficient to shape hard to
work materials.
High velocity forging, single blow, hammers require less

moving weight than do conventional hammer to achieve
the same impact energy per blow.
This machine also requires considerably less space than

the conventional forging press.
40
PRINCIPLE OF OPERATION:
Pneumatic-mechanical forging machines
use:
the energy stored in a compressed gas

e.g. nitrogen
the energy released from burning fuel

(petrol) oxidizer mixture to accelerate a
ram to a high velocity for accomplishing
a deformation stroke or hammer.
41
In the gas operated pneumatic mechanical machines, energy in obtained by expanding
A High pressure gas to drive a piston down a cylinder. In most machines, the
pressurized gas is stored and made to act on the top of the ram with the help of quick
release mechanism for rapid acceleration of the ram. The gas accelerates the ram to
high speeds. During the process there is a very rapid build up on the work piece.
Subsequent to each hammer blow the gas is recompressed. The original quantity of
gas is used time after time or no loss, resulting in very low operating cost.
Repeatability is an important feature.
42
There is an inner frame and an outer frame within which the

inner frame is free to move vertically. As the trigger gas steel
is opened, high pressure gas from the firing chamber acts from
the top face of the ram and forces the ram and the upper die
downward.
Reaction to the downward Acceleration of the ram raises the

inner frame and lower die. The machine is made ready for the
next blow by means of hydraulic jacks that elevate the ram
until the trigger gas seal between the upper surface of the
firing chamber and the ram top is re established.
The machine uses air springs and thus the shock is not
transmitted to the floor. Therefore, a special foundation is not
needed, and the ,machine can be placed directly on the factory
floor. university
kalasalingam
43
ADVANTAGES OF PNEUMATICMECHANICAL FORGING :
Metals difficult to forge by other methods can be forged successfully.
Complex parts can be forged in one blow.
Forging are made to size or within a minimum of machining allowance.
Dimensional accuracy, surface details and often, surface finish are improved.
Draft allowances can be reduced.
Severe deformation results in greater gain refinement in some metals.
Deep, thin sections can be forged.
44
DISADVANTAGES OF PNEUMATICMECHANICAL FORGING :

1.
Process generally is limited to symmetrical parts.
2.
Sharp corners and small radii can not be forged without causing
undue die wear.
3.
The production rate is about the same as in hammer or hydraulic

press forging, but slower than in mechanical press forging.
4.
Part size is limited to about 10 kg fore carbon steel forging, and to

lesser weights for forging made of stainless steel or heat resisting
alloys.
45
MECHANICAL FORGING :
1. Symmetrical or concentric forging such as gears
and wheels.
2. Parts with thin webs and high rib height to width
ratios.
3. Forging of super alloys, refractory alloys, as cast
materials, low alloy steels, aluminum alloys,
titanium alloys, stainless steels etc.
4. Turbine blades and turbine wheels.
5.
Valve bodies.
6. Rifle parts.
7. Missile components.
8. Housings for electronic devices.
9.
Engine housings.
46
ECONOMIC CHARACTERISTICS
When making a cost comparison to aid in
selecting in between one of these special
processes and a conventional one, or when
choosing
between
two
different
special
processes, each of which appears capable of

accomplishing
engineer
is
the
necessary
advised
forming,
therefore,
to
the
contact
manufacturers of the respective equipment to

obtain the most current information available.
47
Experience
indicates that
the HVF processes are
ECONOMIC
CHARACTERISTICS
generally more useful in the production of
smaller quantities of parts. For the production of
small number of parts, the unit cost makes a
HVF operation more favorable because of the
generally lower initial cost of tooling, capital
equipment etc. However as the number of parts
is increased and the unit cost for the
conventional method becomes the lower .In
industries that produce extremely large numbers
of parts, such as the stamping industry, are not
48
economically feasible for most HVF techniques.
CAPABILITY OF HVF PROCRSSES

Characteristics
Electro hydraulic Forming

Bridge wire
Spark discharge
High Explosive(stand-off)
Metal working
operations
Tube bulging,
drawing sizing,
flanging, coining ,
blanking, stretching
Tube bulging, sizing,

flanging, expanding, coining ,
blanking, stretching,
embossing
Draw forming, sizing,

flanging, expanding,
coining
,blanking,stretching,embossi
ng,beading,joining
Size limitations
6.1542mm diameter
or larger
6.1542mm diameter or larger
Limited only by available

blank size
Shape
complexity
Complex surface and

shapes, especially
tubular
Complex surface and shapes,

especially tubular
Small and intricate, large and

simple
Capital
investment
Moderate
Moderate
low
Tooling cost
low
low
low
Labor cost
moderate
moderate
moderate
Production rate
360 parts per hr

depending on part
and equipment
360 parts per hr depending on

part and equipment
0.5-4 parts per hr or less

depending on part and
facility
49

Characteristics
Electro hydraulic Forming

Bridge wire
Spark discharge
High
Explosive(stand-off)
Cycle time
Long
medium
medium
Energy costs
low
low
high
Safety considerations
Equipment interlocks, high

voltage safety practices,
trained personnel

trained personnel
Trained personnel
Method of energy
release
Vaporization of wires
Vaporization of medium
Chemical detonation
Pressure wave
velocity
20,000
(6096)
20,000
(6096)
4,000 to 25,000
(1219-7620)
Pressure wave
duration
microseconds
microseconds
microseconds
Energy range(KJ)
20,000 to 175,000
(27 to 237)
10,000 to 110,000
(13.5 to 150 )
100,000 to 2,000.000
(136-2712) per lb of
explosive, up to 100 lb
45 kg detonator
Work-piece
deformation
velocity(m/s)
50 to 700
(15-213)
50 to 700
(15-213)
60 to 400
(18 to 122)
Energy transfer
Water or other suitable liquid Water or other suitable liquid
medium
Water, elastomers sand,

50
molten salts

Characteristics
High Explosive(direct
contact)
Metal working
operations
draw forming, sizing,

Hardening,welding,
flanging, expanding,
perforating, cladding, powder
coining , blanking, stretch
compacting
forming,embossing,beading
, cutting, powder
compacting, joining,
Hot, warm, cold forming

water compacting,
powder forging,
cropping, blanking,
piercing, coining
Size limitations
Part size not limiting
0.1-72(2.5-1830mm) diam. and

larger in some operations
Up to 24 (610mm) diam.
larger on future
machines
Shape complexity
Simple shapes
Compound surfaces, corrective

forming on large complex
shapes
Complex shapes thin

forged sections
Capital investment
low
Moderate to high
moderate
Tooling cost
None to low
High if work coil is regarded as moderate

part of tooling
Labor cost
moderate
Moderate to low
moderate
Production rate
0.5-4 parts per hr or less

depending on part and
facility
Up to 12,000 parts per hr for

simple parts and automated
transfer equipment
60 to 100 parts per hr

with automatic
equipment, depending
upon part complexity
Electromagnetic
Mechanical-Pneumatic
forging
51
ECONOMIC CHARACTERISTICS
Characteristics
High Explosive(direct
contact)
Electromagnetic
MechanicalPneumatic forging
Cycle time
medium
Medium to short
long
Energy costs
high
low
moderate
Safety
considerations
Trained personnel

trained personnel
Guards and shields,

trained personnel
Method of energy
release
Chemical detonation
Expanding magnetic field
Quick-release valve
Pressure wave
velocity
4,000 to 25,000
(1219-7620)
Not applicable
Not applicable
Pressure wave
duration
Microseconds
Microseconds
Microseconds
Energy range(KJ)
0.5-8 psf high explosive
0-175,00(0-237)
Up to
400,000(542)
Work-piece
deformation
velocity(m/s)
Not applicable
50-1000(15-305)
50-700(15-213)
Energy transfer
Direct contact or buffer
Magnetic field (to be
medium
kalasalingam universitymaterial
operated in vacuum)
High velocity
52
ram
REFERENCES :
Production Technology
Materials and
by O.P.Khanna, Dhanpat Rai Publishers,1998.
Processes in Manufacturing by DeGarmo, Black & Kosher, Prentice-
Hall Publishers, 1997

archive.metalformingmagazine.com/1997/01/7mfjan5.htm
www.metalwebnews.com/howto/explosive-forming/explosive-forming.html
en.wikipedia.org/wiki/Electromagnetic_forming
www.fsb.hr/deformiranje/Presentation_Wentzel_TNO_PML_Rijswijk.pdf
www.fsb.hr/deformiranje/Presentation_Wentzel_TNO_PML_Rijswijk.pd
web.mit.edu/3.082/www/team1_s03/presentation4.10.ppt
www.engineershandbook.com/MfgMethods/ehforming.htm
en.wikipedia.org/wiki/Electromagnetic_forming
www.iap.com/metalfor.html
54

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I.

DEPARTMENT OF MECHANICAL ENGINEERING

SHEET METAL FORMING

HIGH VELOCITY FORMING

High velocity forming processes began to make

Requirements such as the introduction of super

In high velocity forming of metals, the metal is

HIGH VELOCITY FORMING

Releasing compressed gases.

Discharging powerful electrical sparks or

TYPES OF HIGH VELOCITY

Pneumatic- mechanical high velocity forging..

Explosive forming has evolved as one of the most dramatic

In this process the punch is replaced by an explosive charge.

In Explosive Forming chemical energy from the explosives is

Methods of Explosive Forming

The explosives are used in many forms- rod, sheet,

In this method, the explosive charge is held in

The system used for Standoff

Figure 1 shows an arrangement of Standoff Explosive

forming operation. The die assembly is put together on the

Low Explosives in which the ammunition burns rapidly rather

High Explosive which have a high rate of reaction with a large

Advantages of Explosive Forming

Low capital investment is required to adapt the process to

Large and expensive presses are not needed for forming.

Component is generally formed in one shot only.

In general terms, the ultimate strength and yield strength are

Large size parts unable to be handled successfully by

The technique has not been developed to the

The noise developed during forming and the

The ability to generate high intensity shock waves by discharging stored

Spark discharge in a liquid was pointed out as a potential source of power

Basic research on under water condenser discharges was the subject of

Electro hydraulic forming involves the conversion of

METHODS TO CONVERT ELECTRICAL

Capacitor discharge through a gap : Voltages of

METHODS TO CONVERT ELECTRICAL ENERGY

Capacitor discharge through a wire : provides better control than the

In electrohydrauylic forming, electrical energy replaces the explosive used

ADVANTAGES OF EHF OVER

Many designs requiring standard operations have some

Large amounts of energy can be directed into isolated areas as

Reproducibility is another main advantage.

One of the most significant limitations of the process is the

Materials having critical impact velocities below 30 meters

Neither is EHF of parts from materials having low ductility,

A wide range of part sizes are producible by

The process is widely accepted in aerospace

One of the earliest developments in producing a short duration,

Harvey and Brower, around 1958, demonstrated the application

In 1962, first magnetic commercial forming machine was

Using this technique, it is possible to apply to a metallic work

A basic magnetic pulse metal

An insulated induction coil is either

wrapped around, or placed within the

The power source is a capacitor bank.

Magnetic pulse forming machines

As a very high momentary currents are passed

Energy storage capacity and ability of the unit to

ADVANTAGES OF MPF OVER

The pressure is applied to the work piece through the

Since no static forces are involved in the process,