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    High Energy Rate Forming (Introduction)

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    Gururaj Gadad
    High Energy Rate Forming (HERF) involves forming metal parts at extremely high pressures through methods like explosive forming and electrohydraulic forming. Some key advantages include being able to form materials not possible through conventional forming, low die costs, good tolerances, and low production costs. HERF was initially used for thin sheet metals but now also includes applications like compacting metal powders, forging, cold welding, extruding, and cutting. Explosive forming uses controlled explosions to form parts, and can employ low or high explosives. Electrohydraulic forming uses electrically generated hydraulic forces.

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    High Energy Rate Forming (Introduction)

    Uploaded by

    Gururaj Gadad
    131 views19 pages
    High Energy Rate Forming (HERF) involves forming metal parts at extremely high pressures through methods like explosive forming and electrohydraulic forming. Some key advantages include being able to form materials not possible through conventional forming, low die costs, good tolerances, and low production costs. HERF was initially used for thin sheet metals but now also includes applications like compacting metal powders, forging, cold welding, extruding, and cutting. Explosive forming uses controlled explosions to form parts, and can employ low or high explosives. Electrohydraulic forming uses electrically generated hydraulic forces.

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    High Energy Rate Forming (HERF) involves forming metal parts at extremely high pressures through methods like explosive forming and electrohydraulic forming. Some key advantages include being able to form materials not possible through conventional forming, low die costs, good tolerances, and low production costs. HERF was initially used for thin sheet metals but now also includes applications like compacting metal powders, forging, cold welding, extruding, and cutting. Explosive forming uses controlled explosions to form parts, and can employ low or high explosives. Electrohydraulic forming uses electrically generated hydraulic forces.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    131 views19 pages

    High Energy Rate Forming (Introduction)

    Uploaded by

    Gururaj Gadad
    High Energy Rate Forming (HERF) involves forming metal parts at extremely high pressures through methods like explosive forming and electrohydraulic forming. Some key advantages include being able to form materials not possible through conventional forming, low die costs, good tolerances, and low production costs. HERF was initially used for thin sheet metals but now also includes applications like compacting metal powders, forging, cold welding, extruding, and cutting. Explosive forming uses controlled explosions to form parts, and can employ low or high explosives. Electrohydraulic forming uses electrically generated hydraulic forces.

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    High Energy Rate Forming (Introduction)

    This includes number of operations by which parts are produced at


    extremely high pressure (some times called as high velocity form ing)

    ÿ Some material which are not possible by conventional forming ca n be


    formed by this method.

    ÿ Advantages include low die costs, maintaining good tolerances and


    minimum production costs.

    ÿ Earlier application of this process was focused to forming thin sheet


    metals

    ÿ New applications of HERF include compacting metal powders,


    forging, cold welding, extruding and cutting
    High Energy Rate Forming methods
    ¸ Explosive Forming
    ¸ Electrohydraulic Forming
    ¸ Electromagnetic Forming

    Explosive Forming
    ÿ Explosive Forming has proved to be excellent method of utilizing
    energy at a high rate, since the gas pressure and rate of detonation can
    be carefully controlled.
    ÿ Both high and low explosives can be used.
    ÿ Low explosives such as explosive gases and gun cartridges are
    commonly used for light duty applications.
    ÿ Low explosive forming process is performed in a confining die which
    completely encloses the workpiece.
    ÿThis confinement maximizes the explosion energy, which is transferred
    to the workpiece. (two examples)
    An example of low explosive forming process
    (confined combustible gas system)
    An example of low explosive forming process (confined cartridge system)

    ÿ Low explosive forming is useful for high precision applications


    ÿ Low pressures 700 MPa limits its use to thin walled workpieces.
    High explosives
    ÿ High explosives generate pressures exceeding several thousand
    megapascals in a span of 100 microseconds
    ÿ Primacord is the most commonly used explosive because it can be easily
    formed into shaped charges
    ÿ High explosives are an economical form of energy for ex, a kg of
    dynamite costs less than Rs1000 and can release more than 5 million
    Joules of energy.
    ÿ The shock waves sent off by high explosives is so great that the
    explosion does not need to be confined as with low explosives.
    ÿ Either air or water can be used as transfer medium.
    ÿ Both flat and cylindrical configurations can be formed.
    ÿ Water is preferred medium because of its incompressibility.
    ÿ Incompressibility provides greater confinement of the charge and hence
    a higher total impulse efficiency than that provided by air.
    ÿ The size of charge needed to form a given part in water is 80% smaller
    than the charge that would be required in air.
    Two examples of high explosive forming in water medium
    ÿ Dies used for explosive forming must withstand extremely high pressures
    ÿ They are usually made of Mechanite or low carbon steel ( ductile metals)
    ÿ Explosive forming can be accomplished by either with explosives in direct
    contact with the part or with gap in between the two.
    ÿ Contact system forms the highest forming rates but may fracture because of
    non uniform distribution of forces.
    ÿTo assure parts do not fracture the system is performed under water where
    the forces are distributed more uniformly.
    Electrohydraulic forming system

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