CH5 MP

2. Teaching Scheme & Examination
Scheme
Theory/Lectures – 3 Hrs. /Week
Practical– 2Hrs. /Week
ESE: 70 Marks
ISE: 30 Marks
ICA – 25 Marks
OE: 25 Marks

3. Syllabus:
.Unit-5:
Advanced Forming Processes
Introduction to advanced forming
process, High energy rate forming
process- explosive, Electro-
hydraulic, magnetic pulse forming.
Forming with hydrostatic pressure-
hydro mechanical and hydro
forming process

4. Internal Continuous Assessment (ICA):
1. Design of pattern and core for a simple component.
2. Testing of silica sand for grain fineness and clay content.
3. Testing of green sand for green compression strength,
permeability.
4. Study of mold for moisture content and core hardness tester.
5. Study of manufacturing sequence of upset forging with
example.
6. Study of VI characteristic of welding process.
7. Visit to Foundry unit.
8. Visit to forging shop.

5. Text Books
• 1. Heine, Lopar, Rosenthal, Principles of Metal
Casting.
• 2. N.D. Titov, Foundry Practice.
• 3. P.L. Jain, Principles of Foundry Technology.
• 4. P.N.Rao, Manufacturing Technology:
Foundry, Forming and Welding.
• 5. Production Technology by P.C. Sharma

6. • Manufacturing Processes (Title of the
Subject)
• Manufacturing – To produce or to make
• Processes – Method or way of doing

7. High Energy Rate Forming
High energy rate forming is the forming of sheet
metal by a high energy surge or delivered over
a very short time. Since the forming of the
metal occurs so quickly, desirable materials for
(HERF) will be ductile at high deformation
speeds.

8. Explosive forming
• An explosive forming is one of the techniques
to form a metal plate using high shock
pressure from the explosion. An explosive
releases its energy instantly so that an
extremely high pressure with short duration
occurs at the instance of explosion

10. • Explosive forming is a metalworking technique in
which an explosive charge is used instead of a
punch or press.
• It can be used on materials for which a press setup
would be prohibitively large or require an
unreasonably high pressure, and is generally much
cheaper than building a large enough and
sufficiently high-pressure press; on the other hand,
it is unavoidably an individual job
production process, producing one product at a
time and with a long setup time.
• There are various approaches; one is to place
metal plate over a die, with the intervening space
evacuated by a vacuum pump, place the whole
assembly underwater, and detonate a charge at an
appropriate distance from the plate.

12. • Electrohydraulic forming is a type of metal
forming in which an electric arc discharge in
liquid is used to convert electrical
energy to mechanical energy and change the
shape of the workpiece.
• A capacitor bank delivers a pulse of high
current across two electrodes, which are
positioned a short distance apart while
submerged in a fluid (water or oil).
• The electric arc discharge rapidly vaporizes the
surrounding fluid, creating a shock wave.
• The workpiece, which is kept in contact with
the fluid, is deformed into an evacuated die.

13. • Electroh ydraulic forming (EHF) is based on the
ultra-high-speed deformation of metal using
shockwaves in water. Using the discharge of current
from a capacitor bank, an electric arc is generated in
water between two electrodes. This electric arc
vaporizes the surrounding water, converting
electrical energy into an intense shockwave of
mechanical energy.
• The shockwave simultaneously transforms the metal
workpiece into a visco-plastic state and accelerates
it into a die, enabling forming of complex shapes at
high speeds in cold conditions. All of which happens
in a matter of milliseconds; total cycle time of
seconds including charging time of the system.

14. • Advantages of EHF:
• A single-step process (rather than progressive
stamping)
• Fine details and sharp lines can be easily formed
• Forming of male and female shapes (negative and
positive)
• Only a single one-sided die is required
• Extremely fast
• Equipment has small footprint
• No need for a press – the forming chamber is a
self-balanced system

15. Magnetic Pulse Forming
• The electromagnetic forming process (EMF)
is a high strain rate forming process with the
potential to significantly increase the
formability of aluminum alloys. The process
uses electromagnetic pressure to form the
workpiece. The forming pressure is generated
when capacitors are discharged through a coil.

17. The electromagnetic forming method uses a high intense magnetic
field to deform the material. This process is primarily used for the
forming of good conducting materials like copper, aluminum,
silver etc. This method can also be used for materials of poor
electrical conductivity such as stainless steel.
Electromagnetic forming (EM forming or magneforming) is a
type of high-velocity, cold forming process for electrically
conductive metals, most commonly copper and aluminium.
The workpiece is reshaped by high-intensity pulsed magnetic
fields that induce a current in the workpiece and a corresponding
repulsive magnetic field, rapidly repelling portions of the
workpiece.
The workpiece can be reshaped without any contact from a tool,
although in some instances the piece may be pressed against a die or
former.
The technique is sometimes called high-velocity
forming or electromagnetic pulse technology.

18. Hydroforming
• Hydroforming is a specialized deep draw
process that uses high-pressure rubber to
shape and form metal workpieces.
• There are two types of hydroforming; sheet
hydroforming and tube hydroforming.

19. Sheet Hydroforming
In this process, the stamping forming operations are replaced with a single forming process
that uses water pressure to force the sheet metal into the shape of just one half of the die .

20. Sheet Hydroforming is a metal forming process that uses
pressurized hydraulic fluid in a flexible diaphragm to shape
sheet metal against a single, un-mated tool.
The process can create a wide range of complex geometric
shapes from a variety of materials including aluminum, steel,
stainless, titanium, copper, composites, and more.
Sheet hydroforming presses can combine or even replace
different metal forming processes including spinning, press
brake forming, traditional draw forming, rubber pad forming,
progressive die forming, and more.
These machines can also consolidate multiple steps into a
single cycle, virtually eliminating secondary finishing
processes such as polishing, annealing, or welding.

21. Tube Hydroforming
• Tube hydroforming is the expansion of metal
tubes into a shape using two die halves,
which contain the raw tube.
• Hydroforming is used to replace the older
process of stamping two part halves and
welding them together.

24. • The tube is placed in a special die
• The fluid flows into the die
• The tube is formed by the action of the fluid under pressure
(in some cases also due to the action of thrust actuators)
• The hydroformed tube is removed from the die
• By this process, tubes are formed into different shapes using
internal pressure and axial compressive loads simultaneously
to force a tubular blank to conform to the shape of a given die
cavity.
• The hydroformed tubes reach much superior aesthetic and
functional quality levels to those obtained with traditional
processes. The hydrostatic pressure, that deforms the tubes,
ensures that every single part has endured the same uniform
pressure and, consequently, the absence of spring-back as
well as great reliability and rigidity.

25. Applications:
• Aerospace
• Automotive
• Cookware
• HVAC
• Sanitation
• Medical
• Hydroforming advantages:
• Simplification and reduction of additional operations.
• No junction operations.
• Reduction of the amount of special equipment.
• Reduction of overall costs.