Electrohydraulic Forming of Sheet Metal金属板材电液成形.pptVIP

Electrohydraulic Formingof Sheet Metal Rachel Sharp Corinne Packard Isaac Feitler Hao Hu Today Effects of high-velocity metalworking Update on progress Design alterations Next steps High-Velocity Metalworking Includes electrohydraulic, electromagnetic, explosive, and pneumatic-mechanical processes Deformation velocities 100-1000 fps Hydraulic press- 0.2 fps Mechanical press- up to 5 fps Drop hammer- 1-20 fps Strain rate and fracture initiation Low ε-rate Necking in a small area Little plastic deformation in bulk High strain rate Necking initiates and area strain-hardens before localized thinning occurs Velocity varies linearly, until necking Velocity gradient forms Non-uniform inertial forces produce tensile stresses in material outside of neck Advantages of Electrohydraulic Forming Over low ε-rate pressing- Some metals can only be formed at high rates Only one die needed Tubular designs possible Closer thickness tolerances can be achieved Over explosive forming- Much slower production rates with explosives Design Decisions Pressure Vessel Design Hemisphere chosen over cylinder to reduce stress concentrations Considerations Epoxy was chosen for ease of casting, electrical insulation, fracture resistance 2-3” of high-strength epoxy needed for safety Curing issues —limited suppliers Cast into steel pipe with 10” inside diameter to convert from tension to compression on the epoxy Pipe scrap needed, found in Southampton Calculations Considerations Viton rubber sheet chosen to seal between pressure vessel, workpiece, and die Cast metal for dies—easier and less expensive than machining entire parts Copper electrodes—high conductivity and availability Steel plate—strength and resistance to bending Die progress CAD drawings of hemispherical, conical, and automobile mirror shapes Capacitor bank update Progress Obstacles Epoxy is a special formulation and will take 6wks ? not feasible Other options investigated and debated Plaster compounds or cast metal Bored steel Centr