HIGH ENERGY RATE FORMING

 IT IS A PROCESS THAT FORM PRODUCTS AT VERY HIGH VELOCITIES AND EXTREMELY

HIGH PRESSURE.
 THIS IS CALLED AS HIGH ENERGY RATE FORMING (HERF).
 LARGE AMOUNT OF ENERGY IS APPLIED FOR A VERY SHORT INTERVAL OF TIME.
 HIGH PARTICLE VELOCITIES ARE PRODUCED IN CONTRAST WITH CONVENTIONAL
FORMING PROCESS. THE VELOCITY OF DEFORMATION IS ALSO VERY LARGE AND
HENCE THESE ARE ALSO CALLED HIGH VELOCITY FORMING (HVF) PROCESSES.
 HERF PROCESS USED SHORT BURST OF ENERGY THAT IS TRANSMITTED TO THE PART
SURFACE THROUGH A MEDIUM (WATER/AIR).
 The resulting force or shockwave acts to force the part into a die cavity that has
the desired shape of finished product.
 High energy required for small interval time.
 Many metals tend to deform more rapidly under extra fast application of load
which make these processes useful to form large size parts out of these most
metals including those which are difficult to form.
 Material that are difficult to form in conventional methods due to spring back
effect will undergo large plastic deformation with almost no spring back effect
when HERF is used.
TYPES OF HIGH ENERGY RATE
FORMING
1. EXPLOSIVE FORMING
2. ELECTRO HYDRAULIC FORMING
3. MAGNETIC PULSE FORMING
 EXPLOSIVE FORMING:- Explosive forming is a process in which forces
produced by an explosion are used to shape a workpiece. The explosive energy
replaces the male part of the tool that is used in regular forming processes.

 ELECTRO HYDRAULIC FORMING:-  It is one of the high-speed forming

process that uses high-voltage discharge in liquid.

 MAGNETIC PULSE FORMING:- It is a high-speed forming process in which

electromagnetic force is used to deform the workpieces.
ADVANTAGE
 Production rates are higher, as parts are made at a rapid rate and thus these process are also called
high velocity forming process.
 Die costs are relatively lower.
 It is possible to form most metals including difficult to form metals.
 No or minimum spring back effect on the material after the process.
 Production cost is low as power hammer (or press) is eliminated in the process.
 Complex shapes / profiles can be made much easily. as compared to conventional forming.
DISADVANTAGE

 Not suitable to highly brittle materials.

 Source of energy (chemical explosive or electrical) must be handled carefully.
 Highly skilled personnel are required from design to execution.
 Dies need to be much bigger to withstand high energy rates and shocks and to
prevent cracking.
APPLICATION

 Bending thick tubes/ pipes (up to 25 mm thick).

 In ship building - to form large plates / parts (up to 25 mm thick).
 Space application
 In ship building – to form large plates/parts(up to 25mm thick).