Examples of How Increased Formability through High Strain Rates Can Be Used in Electro-Hydraulic Forming and Electromagnetic Forming Industrial Applications

Abstract

In order to take up some challenges in metal forming coming from the recent environmental stakes, Electromagnetic Forming and Electro-Hydraulic Forming processes have been developed at the industrial scale, using the advantages of high strain rates. Such progress has been possible in particular thanks to the emergence of strongly coupled simulation tools. In this article, some examples have been selected from some industrial applications in deep forming, postforming, embossing, and complex shapes forming. It shows how in particular, the increase in formability can bring benefits to solve customer issues in the automotive, luxury packaging, aeronautic, and particles accelerator sectors. Some simulation results are presented to explain how this highly dynamic forming occurs for each of these applications.

Local Temperature Development in the Fracture Zone during Uniaxial Tensile Testing at High Strain Rate: Experimental and Numerical Investigations

“…Three samples were tested for each of the strain rates considered. In the uniaxial tensile test, the nominal strain rate can be calculated directly from the nominal traverse velocity, v, with knowledge of the measurement length, L, via Equation (1).…”

“…High-speed production processes such as electromagnetic or electrohydraulic forming and high-speed impact cutting have a high potential for industrial production because of the many advantages compared with standard processes, such as high deformation capacity, high shear quality, etc. [1][2][3]. It is well known that the availability of an accurate FEM modeling for molding processes is a key means for industrial implementation of technologies and therefore enables the exploitation of process-specific advantages.…”

Experimental investigation of the pulse duration on the efficiency and electrode wear of electrohydraulic forming process

“…Furthermore, controlling pressure waves was crucial to enhance process efficiency [13]. Recent studies aimed to increase the number of electrodes in tooling and explore different chamber shapes and process sequences like in [10,23,24] to improve the efficiency of pressure wave actions on the workpiece. The influence of pulse duration was also emphasized in the literature by [13].…”

“…Despite the potential benefits of these forming processes in various sectors, including transportation, automotive parts, medical tools, joining, packaging, and forming different machinery parts, there has been a lack of research activity over the past 40 yr. Some studies can be noticed dedicated to setting up of complex numerical simulations or to studying the formability of low ductility material like aluminum alloys, nickel alloys, magnesium alloys, stainless steels, advanced high-strength steels (AHSS), highstrength steels (HSS) titanium, Inconel 718 like in [9] or more recently in [10].…”

Impulse-Based Manufacturing Technologies

“…The application examples consider the formation of deep or complex geometries, embossing, and post-forming to shape sharp edges. They show that, depending on the manufacturing task, electromagnetic or electrohydraulic forming could be suitable [9]. The contribution of Mamutov et al also deals with the implementation of electrohydraulic forming in industrial manufacturing.…”