short time to a bank of capacitors connected in parallel.

(The amount of electrical

energy stored in the bank can be increased either by adding capacitors to the bank or
by increasing the voltage). When the charging is complete, which takes very little time, a
high voltage switch triggers the stored electrical energy through the coil. A high
intensity magnetic field is established which induces eddy currents into the conductive
work piece, resulting in the establishment of another magnetic field. The forces
produced by the two magnetic fields oppose each other with the consequence that there
is a repelling force between the coil and the tubular work piece that causes permanent
deformation of the work piece.

Electro Hydraulic Forming

Electro hydraulic forming (EHF), also known as electro spark forming, is a process in
which electrical energy is converted into mechanical energy for the forming of metallic
parts. A bank of capacitors is first charged to a high voltage and then discharged across
a gap between two electrodes, causing explosions inside the hollow work piece, which
is filled with some suitable medium, generally water. These explosions produce shock
waves that travel radially in all directions at high velocity until they meet some
obstruction. If the discharge energy is sufficiently high, the hollow work piece is
deformed. The deformation can be controlled by applying external restraints in the form
of die or by varying the amount of energy released.

Explosive forming process

Explosive forming, is distinguished from conventional forming in that the punch or
diaphragm is replaced by an explosive charge. The explosives used are generally high
explosive chemicals, gaseous mixtures, or propellants. There are two techniques of
high explosive forming: stand off technique and the contact technique.
1. Introduction and Overview

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.

1.1 History of Explosive Forming

Explosive forming was first documented in 1888. It was used in the engraving of
iron plates. In this engraving, the explosive was placed in direct contact with metal,
and the thickness of the explosive layer on the plate determined the depth of indention
made after detonation.

As early as the 1950s, aerospace companies in the United States, such as

Rocketdyne, Aerojet General Corporation, and Ryan Aeronautical were using explosive
forming for the manufacture of complex curved aerospace components. Explosive
forming was especially important in the development of short-production-run missile
componentsparticularly for the curved domes of missiles and rocket nose cones.
During this time, the Soviet Union also began using explosive forming in their
rocket industries for large curved panels.
1.2 Other forms of Explosive Metal Working
There are numerous types of metalworking done with explosives. This paper will
focus only on explosive forming. However, some other metal working techniques are:

Explosive welding
Explosive cutting
Explosive powder forming
Explosive sheet lamination
Explosive coating
Explosive stress relieving
Explosive compaction
Explosive cleaning

1.3 Types of Explosive Forming

Explosive forming can be separated into two different categories: contact
operations and standoff operations.

Contact operations place the explosive in direct contact with the metal.
Standoff operations places the explosive charge some distance away from the
workpiece.

[a] Standoff Technique

The sheet metal work piece blank is clamped over a die and the assembly is lowered
into a tank filled with water. The air in the die is pumped out. The explosive charge is
placed at some predetermined distance from the work piece, see Fig 1.1. On detonation
of the explosive, a pressure pulse 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.
Fig 1.1 Sequence of underwater explosive forming operations.(i) explosive charge is set in position (ii) pressure pulse
and gas bubble are formed as the detonation of charge occurs, (iii) workpiece is deformed, and (iv) gas bubbles vent
at the surface of water.
The system used for Standoff Method consists of following parts: -

1) An explosive charge
2) An energy transmitted medium
3) A die assembly
4) The work piece

The die assembly is put together on the bottom of a tank. Workpiece is placed on the die and
blankholder placed above. A vacuum is then created in the die cavity. The explosive charge is
placed in position over the centre of the workpiece. The explosive charge is suspended over the
blank at a predetermined distance. The complete assembly is immersed in a tank of water.

After the detonation of explosive, a pressure pulse of high intensity is produced. A gas bubble is
also produced which expands spherically and then collapses until it vents at the surface of the
water. When the pressure pulse impinges against the workpiece, the metal is displaced into the
die cavity.

a.1Transmission Medium
Energy released by the explosive is transmitted through medium like air, water, oil, gelatin,
liquid salts. Water is one of the best media for explosive forming since it is available readily,
inexpensive and produces excellent results. The transmission medium is important regarding
pressure magnitude at the workpiece. Water is more desirable medium than air for producing
high peak pressures to the workpiece.

The use of water as the energy transfer medium ensures a uniform transmission of
energy and muffles the sound of the explosive blast.

Explosive forming

The peak pressure generated in water is given by the expression

p = peak pressure

K = constant for type of explosive

W = weight of the explosive

R = distance of explosive from workpiece

a = constant
[b] Contact Technique
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
pressures (upto 30,000MPa) on the surface of the work piece resulting in metal
deformation, and possible fracture. The process is used often for bulging tubes, as
shown in Fig 1.2

Fig 1.2 Schematic illustration of contact technique of explosive forming

2. Explosives

Explosives are substances that undergo rapid chemical reaction during which heat and large
quantities of gaseous products are evolved. Explosives can be solid (TNT-trinitro toluene), liquid
(Nitroglycerine), or Gaseous (oxygen and acetylene mixtures). Explosives are divide into two
classes; Low Explosives in which the ammunition burns rapidly rather than exploding, hence
pressure build up is not large, and High Explosive which have a high rate of reaction with a large
pressure build up. Low explosives are generally used as propellants in guns and in rockets for the
propelling of missiles.

Property High Explosives Low Explosives

Method of
Primary HE-ignition, spark, flame, or impact Ignition
initiation
Secondary HE-detonator, or detonator and
booster combination
Conversion
Microseconds Milliseconds
time+
Pressure up to about 4,000,000psi up to about
 40,000psi

+ Time required to convert a working amount of high explosive into high-pressure gaseous products

Fig: 2.1 Three general methods for explosive forming using high explosives

3. Die Materials
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 tolerances are not critical, while for longer runs higher strength die
materials are required. Kirksite and plastic faced dies are employed for light forming operations;
tool steels, cast steels, and ductile iron for medium requirements.

Material of Die Application Area

Kirksite Low pressure and few parts

Fiberglass and Kirksite
Fiberglass and Concrete
Epoxy and Concrete
Ductile Iron
Concrete
Low pressure and few parts
Low pressure and large parts
Low pressure and large parts
High pressure and many parts
Medium pressure and large parts

The process is versatile a large variety of shapes can be formed, there is virtually no
limit to the size of the work piece, and it is suitable for low quantity production as well.

4. Characteristics of Explosive Forming Process

 Very large sheets with relatively complex shapes, although usually axisymmetric.
Low tooling costs, but high labor cost.
Suitable for low-quantity production.
Long cycle times.

5. Formability Aspects

Formability has been defined as the ability of a sheet metal to be deformed by a specific sheet
metal forming process from its original shape to a defined shape without failure. In normal
explosive forming operations, the major characteristics of the work metal that determine
formability are ductility and toughness. It is general practice not to exceed the elongation, as
determined by the tension testing, in forming a part from the same metal. Following table shows
the comparison of the formability of some metals, using annealed aluminium alloy 1100 as a
basis.

6. Advantages of Explosion Forming

1. Maintains precise tolerances
2. Eliminates costly welds.
3. Controls smoothness of contours.
4. Reduces tooling costs.
5. Less expensive alternative to super-plastic forming.
References
[1] Rinehart J.S and Pearson, John, Explosive Working of Metals, Pergamon Press,
1963. New York.

[2] EXPLOSIVE FORMING - An Overview, by AmitMukund Joshi, Junior Research

Fellow at Indian Institute of Technology, Bombay.

[3] Ezra A.A, Principles and practices of explosive metal working.

[4]Metals Handbook, ASM.

[5]Manufacturing processes for Engineering Materials, 4/e

By Kalpak Jain

[6]Tool materials By Joseph R. Davis

[7] Devices for the explosive forming of workpieces, US Patent 3600921

[8] Tank for explosive forming, US Patent 4174624

Resources
1. (http://www.metalwebnews.com/howto/explosive-forming/explosive-forming.html)
2. TNO PML Website, "Explosive Forming for the Aerospace market"
(http://www.pml.tno.nl/en/products_services/emb/explosive_forming_technology_ae
rospace.html) Accessed 4/06/13.
3. Exploform Company Website. (http://www.exploform.com/old/Zindex2.htm)
Accessed 4/06/13.

4. http://www.exploform.com/old/produktie.htm