Non – Conventional Forming Process
As we know that metal forming process commonly use conventional source of energy. In
addition to these, energy sources such as chemical, magnetic and electrical discharge can be used.
Since, in all such processes, the rate of energy flow is of a much higher order, these are commonly
called High Energy Rate Forming (HERF) process.
High Energy Rate Forming (HERF)
Introduction
As the kinetic energy of a moving body is proportional to the square of its velocity, a large
amount of energy can be supplied by a relatively smaller body moving at high speed.
A number of methods have been developed to form metals through the application of large
amounts of energy in very short time interval. These processes are known as High Energy
Rate Forming (HERF) process.
Many metals tend to deform more rapidly under the ultra-rapid load application rates, used
in these processes.
HERF processes make it possible to form large work piece and difficult to form metals,
with less expensive equipment and tooling than would otherwise be required.
Another advantage of HERF is that there is less difficulty related to spring back.
This is probably associated with two factors. In these processes, high compressive stresses
are set up in the metal when it is forced against the die.
Also, little elastic deformation of the die occurs under the ultra high pressure.
The latter results in a slight over forming of the workpiece and appears like no spring back
has occurred.
High energy rates can be obtained by five different methods:
(a.) Underwater explosions,
(b.) Under water spark discharge (electro-hydraulic techniques),
(c.) Pneumatic mechanical means,
(d.) Internal combustion of gas mixtures, and
(e.) Use of rapid force magnetic fields (electromagnetic techniques).
EXPLOSIVE FORMING
INTRODUCTION
The explosive forming of metals has been known for about 100 years.
Explosive forming was first proposed at the Kharkov Aviation Institute in the 1940’s and
was widely used in the mid 1950’s in the production of oversize parts for rockets and
airplanes.
WHAT IS EXPLOSIVE FORMING PROCESS?
Explosive forming is a manufacturing technique that uses explosions to force metal into
dies and molds.
The explosives are typically either detonated underwater or in direct contact with the
materials.
The technique is useful for short production runs of conventionally difficult to manufacture
parts.
In explosive forming a punch or diaphragm in conventional forming is replaced by an
explosive charge.
Chemical energy from the explosives is used to generate shockwaves through a medium
(mostly water), which are directed to deform the workpiece at very high velocities.
A die is manufactured according to the desired shape of the product. Dies can be made
from a number of materials including concrete, ductile iron, fiberglass and kirk site or
epoxy and concrete.
Forming takes place inside a water tanker “explosion tank” where the die is placed. The
workpiece is situated directly above the die and explosive material placed above that. The
explosive material is typically Trinitrotoluene (TNT), a mixture of acetylene and oxygen or
Nitroglycerine.
When the explosive material is detonated, the resulting shockwave through the transfer
medium (the water) forces the workpiece material into the die, thus assuming its shape.
TYPES OF EXPLOSIVE FORMING
Explosive Forming Operation can be divided into two groups, depending on the position of
the explosive charge relative to the workpiece.
1. Stand – off technique or Unconfined Type
2. Contact technique or Confined Type
1. Stand-off technique or Unconfined Type
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.
Stand-off distance depends on the size of the work, for larger parts it is usually about half
the diameter of the blank.
Fig.: Sequence of underwater explosive forming operation
PRINCIPLE
The work is firmly supported on the die and the die cavity is evacuated.
A definite quantity of explosive is placed suitably in water medium at a definite
standoff distance from the work.
On detonation of the explosive charge, a pressure pulse (or a shock wave) of very high
intensity is produced.
A gas bubble is also produced which expands spherically and then collapses.
When the pressure pulse impinges against the work piece, the metal is deformed into
the die with as high velocity as 120 m/s.
The vacuum is necessary in the die to prevent adiabatic heating of the work which may
lead to oxidation or melting.
Peak pressure ‘P’ generated where the transfer medium is water, can be given by the
expression:
√
𝑃 = 𝑘[ ]a
Where
k = constant dependent upon explosive (21600 for TNT)
W = weight of explosive
R = standoff distance
a = constant, generally taken as 1.15
ROLE OF WATER PROCESS VARIABLES
Acts as energy transfer medium. Type and amount of explosive.
Ensures uniform transmission of energy. Standoff distance - SOD – (Distance
Muffles the sound of explosion. between work piece and explosive)
Cushioning/ smooth application of The medium used to transmit energy.
energy on the work without direct Work size
contact. Work material properties.
2. 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 pressure on the surface of the metal upto several
million psi.
Fig.: Contact method explosive forming process
PRINCIPLE
The explosive charge in the form of cartridge is held in direct contact with the work
piece while the detonation is initiated.
The detonation builds up extremely high pressure (up to 30,000 MPa) on the surface
of the workpiece resulting in metal deformation, and possible fracture.
The process is used often for building tubes.
EXPLOSIVE USED
Explosive are substances that undergo rapid chemical reaction during which heat and large
quantity of gaseous products are evolved.
Explosive can be:
a.) Solid (TNT – trinitro toluene)
b.) Liquid (Nitroglycerine)
c.) Gaseous (oxygen and acetylene mixture)
The type of charge, its location, method and place of its initiating determine the pressure
area of a sheet metal being deformed.
Most distributed types of charges are
a.) Concentrated charge (generally spherical)
b.) Linear (Detonating Cable)
c.) Adjustable Charge
Explosives are divided into two classes:
(a.) Low Explosives in which the ammunition burns rapidly rather than exploding, hence
pressure build up is not large.
(b.) High Explosive which have a high rate of reaction with a large pressure build up.
DIE MATERIAL
Different materials are used for the manufacture of dies for explosive working, for instance
high strength tool steels, plastics, concrete.
Relatively low strength dies are used for short run items and for parts where close tolerance
are not critical, while for longer runs higher strength die materials are required.
Kirk site (An alloy of Al-Zn, can be casted at low temperature) and plastic faced dies are
employed for light forming operations.
Tool steels, cast steels, and ductile iron for medium requirements.
Application areas for dies:
Material of Die Application Area
Kirksite Low pressure and few parts
Fiberglass and Kirksite Low pressure and few parts
Fiberglass and Concrete Low pressure and few parts
Epoxy and Concrete Low pressure and few parts
Ductile Iron High pressure and many parts
Concrete High pressure and many parts
ADVANTAGES AND DISADVANTAGES OF EXPLOSIVE FORMING
ADVANTAGES DISADVANTAGES
Used to form larger parts which High labor cost.
can’t be easily pressed. Suitable for low quantity production.
The explosive used can be of any Due to shock waves and spillage of
mass and shape, so the size of the water it is not suitable to carry out
product is not a concern of matter. indoor.
It can simulate a variety of other It should be done in open air.
conventional metal forming
techniques such as stamp or press
forming and spin forming in a single
operation.
It maintains precise tolerance and
eliminates costly welds.
APPLICATION OF EXPLOSIVE FORMING
Sheet metal panels
Tubing
Housings
Jet engine parts
Missile nose cones
Ducts etc.