High Energy Rate Forming(HERF)
• It can be used to form a wide variety of metals, difficult
to form materials like Titanium and Tungsten alloys, can
be deformed under high strain rates.
• applied a large amount of energy in a very short time
interval
• Large parts can be easily formed by this technique.
• Accuracy of the objects is very high due to no elastic
recovery
• Complex shapes/profiles can be made much easily, as
compared to conventional forming.
Limitations
• Highly skilled personnel are required from design to execution.
• Not suitable to highly brittle materials
• Source of energy (chemical explosive or electrical) must be
handled carefully.
• Dies need to be much bigger to withstand high energy rates and
shocks and to prevent cracking.
• Controlling the application of energy is critical as it may crack
the die or work.
Applications
• In ship building – to form large plates (up to 25 mm thick).
• Bending thick tubes/ pipes (up to 25 mm thick).
• Elliptical domes used in space applications.
• Cladding of two large plates of dissimilar metals
Explosive Forming
• 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 stand off distance from the work.
• TNT and Dynamites for high energy and gun powder for low
energy is used
• On detonation of the explosive charge, a pressure pulse (or a
shock wave) of very high intensity is produced.
• When the pressure pulse impinges against the work (plate or
sheet) metal is deformed into the die with a high velocity of
around 120 m/s.
• Used for parts of thick materials.
Applications:
Aerospace, aircraft industries, Ship building, Elliptical domes in
space applications, etc.
Electro hydraulic Forming
• A sudden electrical discharge in the form of sparks is produced
between electrodes and this discharge produces a shock wave in
the water medium.
• This shock wave deforms the work and collapses it into the die.
• The characteristics of this process are similar to those of
explosive forming.
• The major difference, however, is that a chemical explosive is
replaced by a capacitor bank, which stores the electrical energy.
• The capacitor is charged through a charging circuit.
• When the switch is closed, a spark is produced between
electrodes and a shock wave or pressure pulse is created.
• The energy released and peak pressure is much lesser than
explosive forming but easier and safer
Applications:
cone and other shapes and bulging operations in thinner and small
works.
Electromagnetic forming
OR
Magnetic pulse forming
• The electrical energy is stored in the capacitor bank
• The tubular work piece is mounted on a mandrel having the die
cavity to produce shape on the tube.
• A primary coil is placed around the tube and mandrel assembly.
• The coil produces a varying magnetic field around it.
• In the tube a secondary current is induced, which creates its own
magnetic field in the opposite direction.
• The directions of these two magnetic fields oppose one another and
hence the rigidly held coil repels the work into the die cavity.
• The process is most effective for relatively thin materials and
tubes(0.25 to 1.25 mm thick)
• Work piece must be electrically conductive but need not be
magnetic.
Applications:
Crimping of coils, tubes, wires Bending of tubes into complex shapes
Bulging of thin tubes.
Petro-Forging
OR
Petro-Forge Forming
• In this process, the stored chemical energy of a
hydrocarbon, like petrol or diesel is utilized to move
the dies at very high velocity
• The principle of working is just similar to I.C engine
• It is a piston cylinder- arrangement and a piston
drives a ram and a die.
• After air fuel mixture is ignited in the combustion
chamber pressure increases by 5 to 7 times which
brakes the seal and the high pressure gases act on
the top face of the piston
• The piston ram and die are accelerated at a very
rapid rate and strike up to 250 m/s
Assertion (A) : In magnetic pulse‐forming method,
magnetic field produced by eddy currents is used to
create force between coil and work piece.
Reason (R) : It is necessary for the work piece
material to have magnetic properties.
• Both A and R are individually true and R is the
correct explanation of A
• Both A and R are individually true but R is NOT
the correct explanation of A
• A is true but R is false
• A is false but R is true
