HERF

Metal Forming
High Energy Rate Forming
Department of Mechanical Engineering ,BVOE & RI Nasik
Metal Forming
High energy rate forming processes began to make their mark and grow
in application in 1960.
Requirements such as the introduction of super tough alloys for space

vehicles., supersonic aircraft and the need for shaping incredibly small,
thin and brittle materials for electronic components helped in the growth
of high velocity forming processes.
In high energy rate forming of metals, the metal is shaped in microseconds with pressures generated by the sudden application of large
amounts of energy
Metal Forming

Ductile
Brittle
Spring back
problem
Metal Forming
Detonate
Explosives
Working
material
Metal Forming

Pressures needed for forming are generated by
1.
Detonating explosives.
2.
Releasing compressed gases.
3.
Discharging powerful electrical sparks
4.
Electromagnetic energy
Metal Forming

Advantages of HERF Processes
Production rates are higher, as parts are made at a rapid rate.
Die costs are relatively lower.
Tolerances can be easily maintained.
Versatility of the process it is possible to form most metals including difficult to
form metals.
No or minimum spring back effect on the material after the process.
Production cost is low as power hammer (or press) is eliminated in the process.
Hence it is economically justifiable.
Metal Forming

Advantages of HERF Processes
Complex shapes / profiles can be made much easily, as compared to
conventional forming.
The required final shape/ dimensions are obtained in one stroke (or
step), thus eliminating intermediate forming steps and pre forming dies.
Suitable for a range of production volume such as small numbers,
batches or mass production
Metal Forming

Limitations
Highly skilled personnel are required from design to execution.
Transient stresses of high magnitude are applied on the work.
Not suitable to highly brittle materials
Source of energy (chemical explosive or electrical) must be handled carefully.
Governmental regulations/ procedures / safety norms must be followed.
Dies need to be much bigger to withstand high energy rates and shocks and
to prevent cracking.
The technique has not been developed to the stage where a part can always
be formed on the first shot.
Increase transportation and handling costs.
Metal Forming

Applications
In ship building to form large plates / parts (up to 25 mm thick).
Bending thick tubes/ pipes (up to 25 mm thick).
Crimping of metal strips.
Radar dishes
Elliptical domes used in space applications.
Cladding of two large plates of dissimilar metals.
Metal Forming

Factors to be considered while selecting an HERF process
Size of work piece
Geometry of deformation
Behavior of work material under high strain rates
Energy requirements/ source
Cost of tooling / die
Cycle time
Overall capital investment
Safety considerations.
10
Metal Forming

EXPLOSIVE FORMING
Explosive forming has evolved as one of the most dramatic of the new
metalworking techniques. Explosive forming is employed in Aerospace
and aircraft industries and has been successfully employed in the
production of automotive-related components. Explosive Forming can
be utilized to form a wide variety of metals, from Aluminum to high
strength alloys
In Explosive Forming chemical energy from the explosives is used to
generate shock waves through a medium (mostly water), which are
directed to deform the work piece at very high velocities.
11
Metal Forming

METHODS OF EXPLOSIVE FORMING
The explosives are used in many forms- rod, sheet, granules, liquid, stick
etc. Depending upon the placement of the explosive (charge), the
operations fall into two categories :
1. Stand-off operations ( Open type /Unconfined type )
2. Contact operations ( close type / Confined System)
3. Multiple type
12
12
Metal Forming

Stand-off operations ( Open type/ Unconfined type )
high velocity of around 120 m/s
The vacuum is necessary in the die to prevent adiabatic heating of the work which
may lead to oxidation or melting
13
Metal Forming
Stand-off operations ( Open type / Unconfined type )

Role of water:
i) Acts as energy transfer medium
ii) Ensures uniform transmission of energy
iii) Muffles the sound of explosion
iv) Cushioning / smooth application of energy on the work without direct
contact.
Advantages
i) Shock wave is efficiently transmitted through water and energy is transmitted
effectively on the work
ii) Less probability of damage to work.
iii) Large and thick parts can be easily formed
iv) Economical, when compared to a hydraulic press
14
14
Metal Forming
Stand-off operations ( Open type / Unconfined type )

Limitations:
i) Optimum Stand off distance is essential for proper forming operation.
ii) Vacuum is essential and hence it adds to the cost.
iii) Dies must be larger and thicker to withstand shocks.
iv) Not suitable for small and thin works.
v) Explosives must be carefully handled according to the regulations of the
government
Applications:
Ship building
Radar dish
Elliptical domes in space applications
15
15
Metal Forming

Contact operations ( close type / confined type )
16
Metal Forming

Contact operations ( close type / confined type )
Advantages:
i) Entire shock wave front is utilized as there is no loss in water.
ii) More efficient as compared to unconfined type.
Disadvantages:
i) More hazard of die failure
ii) Vacuum is required in the die
iii) Air present in the work piece (tube) is compressed leading to heating.
iv) Not suitable for large and thick plates.
Applications
Bulging and flaring of tubes.
17
Metal Forming

Multiple type
Energy utilized for forming more than one blank at time
blank are arranged to form close chamber
18
Metal Forming

Explosives used
Solid (TNT - trinitro toluene)
Liquid ( Nitroglycerine)
Gaseous ( oxygen and acetylene mixtures).
19
Metal Forming

Explosives used
Explosive
Relative
power
% TNT
Form of Detonation
charge velocity
m/s
Energy
KJ/Kg
Max.
Pressure
GPa
RDX
(cyclotrimethylene
trinitramine )
170
Pressed
granules
8380
1270
23.4
TNT
(trinitrotoluene )
100
cast
7010
780
16.5
PETN (penta
erythritol tetra
nitrate )
170
Pressed
granules
8290
1300
22.1
20
Metal Forming

Explosives used
Explosive
Relative
power
% TNT
Form of
charge
Detonatio Energy
n velocity KJ/Kg
m/s
Max.
Pressure
GPa
Tetryl
(trinitrophenyl
methylinitramin)
129
Pressed
granules
7835
---
----
Blasting gelatin
99
Cartridge
plastic
7985
1220
17.9
21
Metal Forming

parameters
Low explosives
High explosives
Burns rapidly rather than

exploding & build up is not
very large
High rate of reaction with a

large pressure build up
Method of
initiation
ignition
high energy ignition, spark

flame or impact & detonator can
be used or detonator and
booster combination can also
be used for initiation purposes
conversion
time
milliseconds
microseconds
pressure
40,000 psi
40,00,000 psi
22
Metal Forming

Die material
High strength tool steel
Plastic
Concrete
Kirksite (zmack family of alloy with base metal of Zn ,alloying element of
Al, Mg, Cu.) plastic based dies are employed for light forming operations
Tool steel & ductile iron are used for medium requirement
23
Metal Forming

Die material
Die material
Application area
kirksite
Low pressure & few parts
Fiber glass & kirksite
Low pressure & few parts
Fiber glass & concrete
Low pressure & High parts
24
Metal Forming

Formability Aspect
Formability is the ability of a given metal work piece to undergo plastic
deformation without being damaged. The plastic deformation capacity
of metallic materials, however, is limited to a certain extent, at which
point, the material could experience tearing or fracture.
In normal explosive forming operations, the major characteristics of the
work metal that determine formability as
Ductility
Toughness.
25
Metal Forming

Formability of different material by explosive forming
Inconel X-750
5 % cr steel
1010 steel
Copper
1100-0 Aluminum
Percentage scale
10
20
30
40
50
60
70
80
90 100
26
Metal Forming

Typical HERF Application of huge high pressure tank
easily manufactured
tooling required becomes expensive
27
Metal Forming

Electro Hydraulic forming
The ability to generate high intensity shock waves by discharging stored
electrical energy across electrodes submerged in a liquid medium has been
recognized for a great many years.
Spark discharge in a liquid was pointed out as a potential source of power
in 1944.
Basic research on under water condenser discharges was the subject of
several investigations in the early 1950s.
The first attempts to use electro hydraulic forming ( also called capacitor
discharge forming or spark forming ) process for forming metals were in the
United States in 1953 to punch holes in 1.5 mm steel plates.
28
Metal Forming

29
Metal Forming

1.Spark discharge method
Capacitor discharge through a
gap : Voltages of 10,000 to 30,000
volts are generally used when the
spark discharge method is utilized.
This potential difference will jump
the air gap present between two
electrodes, submerged in the liquid
The spark discharge methods are
most often used for bulging
operations in small parts, but
parts up to 1.5 meter in diameter
can also be formed.
Spark discharge
30
Metal Forming

2. Bridge wire method
Capacitor discharge through a wire :
Better control than Spark discharge
method
Use of lower potential difference is
possible;
A disadvantage of the wire method,
however, is that a new wire is to be
loaded after each shot for parts requiring
multiple shots for reaching the desired
results
Bridge wire
31
Metal Forming

Advantages:
i) Better control of the pressure pulse as source of energy is electrical- which can
be easily controlled.
ii) Safer in handling than the explosive materials.
iii) More suitable if the work size is small to medium.
iv) Thin plates can be formed with smaller amounts of energy.
v) The process does not depend on the electrical properties of the work material.
vi) When EHF is used, the cost of tooling will almost always be less than that for
conventional equipment
32
Metal Forming

Limitations:
i) Suitable only for smaller works
ii) Need for vacuum makes the equipment more complicated.
iii) Proper Stand off distance (SOD) is necessary for effective process.
iv) Materials having critical impact velocities below 30 meters per second are
not practical for elect hydraulic forming
Applications:
Smaller radar dish, cone and other shapes in thinner and small works.
widely accepted in aerospace industries to accomplish bulging, forming,
beading, drawing, blanking and piercing
33
Metal Forming

Electromagnetic forming
Electromagnetic forming (EM forming or magneforming) is a type of high
velocity, cold forming process for electrically conductive metals, most
commonly copper and aluminium
34
Metal Forming

Because of Lenz's Law, the magnetic fields

created within the conductor and work coil
strongly repel each other
A law stating that the direction of an

induced current is always such as to
oppose the change in the circuit or the
magnetic field that produces it.
35
Metal Forming

Types of deformations
(i) Compression (shrinking)
(ii) Expansion (bulging)
36
Metal Forming

Process parameters:
i) Work piece size
ii) Electrical conductivity of the work material.
iii) Size of the capacitor bank
iv) The strength of the current, which decides the strength of the magnetic
field and the force applied.
v) Insulation on the coil.
vi) Rigidity of the coil.
37
Metal Forming

Advantages:
i) Suitable for small tubes
ii) Operations like collapsing, bending and crimping can be easily done.
iii) Electrical energy applied can be precisely controlled and hence the process
is accurately controlled.
iv) The process is safer compared to explosive forming.
v) The pressure is applied to the work piece through the medium of a magnetic
field without any physical contact
vi) Since there is no friction between the magnetic field and the work piece, no
lubricants are required and the process leaves no tool marks
38
Metal Forming

Limitations:
i) Applicable only for electrically conducting materials.
ii) Not suitable for large work pieces.
iii) Rigid clamping of primary coil is critical.
iv) Shorter life of the coil due to large forces acting on it.
39
Metal Forming

Applications:
i) Crimping of coils, tubes, wires
ii) Bending of tubes into complex shapes
iii) Bulging of thin tubes
iv )Tubular members can be joined to end
fittings by magnetic swaging
Fast and cost-effective joining
of non-weldable materials, like
heterogeneous joints; since
the electromagnetic pulse
processes do not use heat to
join materials,
Crimp joints of connectors onto

rubber hoses
Crimp joints of connectors onto electric cables
40
Metal Forming

Characteristics
Electro hydraulic Forming

Bridge wire
Spark discharge
High Explosive(stand-off)
Metal working
operations
Tube bulging,
drawing sizing,
flanging, coining ,
blanking, stretching
Tube bulging, sizing,

flanging, expanding,
coining , blanking,
stretching, embossing
Draw forming, sizing, flanging,

expanding, coining blanking,
stretching, beading, joining
Size limitations
6.1542mm diameter
or larger
6.1542mm diameter or
larger
Limited only by available blank

size
Shape
complexity
Complex surface
and shapes,
especially tubular
Complex surface and

shapes, especially tubular
Small and intricate, large and

simple
Capital
investment
Moderate
Moderate
low
Tooling cost
low
low
low
Labor cost
moderate
moderate
moderate
Production rate
360 parts per hr

depending on part
and equipment
360 parts per hr depending

on part and equipment
0.5-4 parts per hr or less

depending on part and facility
41
Metal Forming

Characteristics

Bridge wire
Spark discharge
Cycle time
Long
Medium
Medium
Energy costs
Low
Low
High
Safety
considerations
Equipment
interlocks, high
voltage safety
practices, trained
personnel
Equipment interlocks, high

voltage safety practices,
trained personnel
Trained personnel
Method of
energy release
Vaporization of
wires
Vaporization of medium
Chemical detonation
Pressure wave
duration
Microseconds
Microseconds
Microseconds
42
Metal Forming

Characteristics

Bridge wire
Spark discharge
Energy
range(KJ)
(27 to 237)
(13.5 to 150 )
100,000 to 2,000.000
(136-2712) per lb of explosive,
up to 100 lb 45 kg detonator
Work-piece
deformation
velocity(m/s)
(15-213)
(15-213)
(18 to 122)
Energy transfer
medium
Water or other
suitable liquid
Water or other suitable

liquid
Water, elastomers sand, molten

salts
43
Metal Forming

Characteristics
High Explosive (direct contact)
Electromagnetic
Metal working operations
Draw forming, sizing, flanging,

expanding, coining , blanking,
stretch forming, embossing, cutting,
powder compacting, joining,
Hardening, welding, perforating,

cladding, powder compacting
Size limitations
Part size not limiting
(2.5-1830 mm) diam. And larger in some

operations
Shape complexity
Simple shapes
Compound surfaces, corrective forming

on large complex shapes
Capital investment
Low
Moderate to high
Tooling cost
None to low
High if work coil is regarded as part of

tooling
Labor cost
Moderate
Moderate to low
Production rate
0.5-4 parts per hr or less depending

on part and facility
Up to 12,000 parts per hr for simple

parts and automated transfer equipment
44
Metal Forming

Characteristics
High Explosive (direct contact)
Electromagnetic
Cycle time
medium
Medium to short
Energy costs
high
low
Safety considerations
Trained personnel
Equipment interlocks, high voltage

safety practices, trained personnel
Method of energy
release
Chemical detonation
Expanding magnetic field
Pressure wave duration
Microseconds
Microseconds
Energy range(KJ)
0.5-8 psf high explosive
(0-237)
Work-piece deformation
velocity(m/s)
Not applicable
(15-305)
Energy transfer medium
Direct contact or buffer material
Magnetic field (to be operated in

vacuum)
45

HERF

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Metal Forming

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Requirements such as the introduction of super tough alloys for space

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Releasing compressed gases.

Discharging powerful electrical sparks

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

High Energy Rate Forming

Stand-off operations ( Open type / Unconfined type )

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Stand-off operations ( Open type / Unconfined type )

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Burns rapidly rather than

High rate of reaction with a

high energy ignition, spark

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Low pressure & few parts

Fiber glass & kirksite

Low pressure & few parts

Fiber glass & concrete

Low pressure & High parts

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming

Department of Mechanical Engineering ,BVOE & RI Nasik

High Energy Rate Forming