Theory of Metal Forming (MME4045)

CHAPTER 7: HIGH ENERGY RATE FORMING

Several processes have been developed to form metals using large amounts of energy applied in a
very short time. Owing to this feature, these operations are called high energy-rate forming
(HERF) processes. They include explosive forming, electrohydraulic forming, and
electromagnetic forming.

Explosive forming
Explosives generally are used for demolition in construction, in road building, and for many
destructive purposes. However, controlling their quantity and shape makes it possible to use
explosives as a source of energy for sheet-metal forming.
Explosive forming involves the use of an explosive charge to form sheet (or plate) metal into a die
cavity. Figure 1 shows the setup. One method of implementing the process is illustrated in figure
2. The work part is clamped and sealed over the die, and a vacuum is created in the cavity beneath.
The apparatus is then placed in a large vessel of water. An explosive charge is placed in the water
at a certain distance above the work. Detonation of the charge results in a shock wave whose
energy is transmitted by the water to cause rapid forming of the part into the cavity.

Figure 1 Explosive forming setup

The peak pressure, p, generated in water is given by the expression,

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 Theory of Metal Forming (MME4045)

from the sheet-metal surface (called the standoff) in meters, and a is a constant, generally taken to
be 1.15.

Figure 2 Explosive forming steps, (a) Setup, (b) Explosive is detonated, (c) Shock wave forms
part and plume escapes water surface

The size of the explosive charge and the distance at which it is placed above the part are largely a
matter of art and experience. Explosive forming is reserved for large parts, typical of the aerospace
industry. A variety of shapes can be formed through explosive forming, provided that the material
is ductile at the high rates of deformation characteristic of this process. The process is versatile, as
there is virtually no limit to the size of the sheet or plate. It is suitable particularly for low-quantity
production runs of large parts, such as those used in aerospace applications. The explosive-forming
method also can be used at a much smaller scale, as shown in figure 3. In this case, a cartridge
(canned explosive) is used as the source of energy. The process can be useful in the bulging and
expanding of thin-walled tubes for specialized applications. The mechanical properties of parts
made by explosive forming are basically similar to those of others made by conventional forming
methods. Depending on the number of parts to be produced, dies may be made of aluminum alloys,
steel, ductile iron, zinc alloys, reinforced concrete, wood, plastics, or composite materials.

Figure 3 Illustration of the confined method of explosive bulging of tubes

Electro-hydraulic forming
Electro-hydraulic forming is a HERF process in which a shock wave to deform the work into a die
cavity is generated by the discharge of electrical energy between two electrodes submerged in a
transmission fluid (water). Owing to its principle of operation, this process is also called electric
discharge forming. The setup for the process is illustrated in figure 4. Electrical energy is
accumulated in large capacitors and then released to the electrodes. Electro-hydraulic forming is
similar to explosive forming. But the energy levels are lower than those in explosive forming. The
pressure developed in the water medium is sufficiently high to form the part. Electro-hydraulic
forming is a batch process and can be used in making various small parts.

Figure 4 Electro-hydraulic forming setup

Electro-magnetic forming
Electro-magnetic forming is the most widely used HERF process. It us also called as magnetic-
pulse forming. In this process, the energy stored in a capacitor bank is discharged rapidly through
a magnetic coil. In a typical example, a ring-shaped coil is placed over a tubular workpiece. The
tube is then collapsed by magnetic forces over a solid piece, thus making the assembly an integral
part (Figure 5(a)).
The mechanics of this process is based on the fact that a magnetic field produced by the coil crosses
the metal tube (which is an electrical conductor) and generates eddy currents in the tube. In turn,
these currents produce their own magnetic field. The forces produced by the two magnetic fields
oppose each other. The repelling force generated between the coil and the tube then collapses the
tube over the inner piece. The higher the electrical conductivity of the workpiece, the higher the

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 Theory of Metal Forming (MME4045)

magnetic forces. It is not necessary for the workpiece material to have magnetic properties. It has
been shown that the basic advantages of this process is that the formability of the material is
increased, dimensional accuracy is improved, and spring back and wrinkling are reduced.
Magnetic coil design is an important consideration for the success of the operation. Plat magnetic
coils also can be made for use in operations such as embossing and shallow drawing of sheet
metals. The process has been found to be particularly effective for aluminum alloys. Electro-
magnetically assisted forming is applied to (a) collapsing thin-walled tubes over rods, cables, and
plugs; (b) compression-crimp sealing of automotive oil filter canisters; (c) specialized sheet-
forming operations; (d) bulging and flaring operations and (e) swaging end fittings onto torque
tubes. A typical tube formed using the process is illustrated in Figure 5(c).

Figure 5 Electro-magnetic forming, (a) Tube formed over a plug, (b) Setup in which coil is
inserted into tubular work part surrounded by die, (c) Formed part.

Review questions
1. With a neat sketch, explain the working principle of explosive forming process.
2. Sketch and explain confined explosive forming process.
3. Write a short note of electro-hydraulic forming process.
4. With a neat sketch, explain the working principle of electro-magnetic forming process.

References:
 M.P. Groover, Fundamentals of Modern Manufacturing, 4(e), John Wiley & Sons, Inc.
USA, 2010.
 S. Kalpakjian & S.R. Schmid, Manufacturing Engineering and Technology, (3e), Addision
Wesley, New York, 1995.