ICHSF 2018
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The 8th International Conference on High Speed Forming (ICHSF 2018) will be held at The Ohio State University in Columbus Ohio May 14-16. The conference is jointly organized by the Ohio State University College of Engineering and the Institute of Forming Technology and Lightweight Components of TU Dortmund University. The Scientific Committee will be managed through the structures of the International Impulse Forming Group.
This conference will be a forum to demonstrate technical innovation and show its direct impact on economic development and the sustainable manufacture of products.
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Recent Submissions
Item Prediction of Achievable Energy Deposition for Vaporizing Foil Actuators(2018-05-15) Hahn, M.; Hansen, S. R.; Gies, S.; Vivek, A.; Daehn, G. S.; Tekkaya, A. E.A novel iterative analytic approach allowing for the prediction of energy deposition into Vaporizing Foil Actuators (VFA) is presented. Besides the process parameters of actuator geometry and pulse generator configuration, it takes into account the energy dependence of the resistivity as well as the rate dependence of the achievable energy deposition. This rate dependency is found experimentally for aluminum foils and subsequently used in the modeling. With an average deviation of less than 15% the predicted energy depositions are in acceptable accordance with the experiments, but only as long as homogeneous Joule heating can be assumed. The proposed model has thus the potential to ease the future VFA process design, e.g. for manufacturing applications.Item 5083 Al/1060 Al/AZ31 Composite Plates Fabricated by Explosive Welding(2018-05-15) Suyuan, Yang; Jiawei, BaoItem Welding of 2024 and 7075 Aluminum Alloys by Vaporizing Foil Actuator(2018-05-15) Meng, Z.; Mao, Y.; Huang, S. Y.; Hua, L.; Vivek, A.; Daehn, G. S.Item Application of Smoothed Particle Hydrodynamics Method in Simulation of Highvelocity Impact Welding(2018-05-15) Nassiri, Ali; Abke, Tim; Vivek, Anupam; Daehn, GlennItem Numerical and Experimental Study of Electromagnetic Crimping(2018-05-14) Kumar, R.; Rajak, A. K.; Kore, S. D.Electromagnetic pulse crimping is a solid state, high speed, and high strain rate joining process. In this process, the flyer is deformed over the base plastically to produce the joint. In this work, copper tube was crimped over the aluminium rod by using single step field-shaper. Finite element analysis, as well as experimental study, was carried out on the single step field-shaper to crimp the copper tube on the aluminium rod. The finite element model was validated based on the measured temperature and outer diameter of the crimped rod. The validated model was used to study the effect of the working length position on the electromagnetic crimping. The variation in the working length position of the field-shaper was analysed to increase the concentration of the electromagnetic pressure at the desired location to produce an effective joint with better mechanical strength. It was found that with the change in the position of the working length of the field-shaper the impact velocity, temperature gen-eration, magnetic field density, and uniformity in crimping of the tube also changes.Item Laser Impulse Generation - Parameter Effects and Applications(2018-05-14) Bovid, StanItem State of the Art in Explosion Welding(2018-05-15) Blakely, MikeItem Supersonic Impact of Metallic Microparticles(2018-05-15) Hassani-Gangaraj, Mostafa; Veysset, David; Nelson, Keith A.; Schuh, Christopher A.Item Atomic Scale Characterization of an Al-Steel Weld Interface(2018-05-15) Sridharan, Niyanth; Vivek, Anupam; Poplowsky, Jonathan; Lee, T.; Daehn, GlennItem Effect of coil to tubular workpiece magnetic coupling on electromagnetic expansion process(2018-05-14) Dond, S. K.; Kolge, Tanmay; Choudhary, Hitesh; Sharma, ArchanaEfficiency of the electromagnetic forming process is very less. Leakage flux contributes to a fraction of total energy loss in the forming process, and it is related to the coupling between the coil and workpiece. The workpiece experiencing Lorentz force should be as close as possible to the tool coil in order to achieve higher utilization of discharge energy. In this paper, experimental and numerical simulation study is performed to observe the coil-tube magnetic coupling effect on tube expansion and thereby on process efficiency. Aluminum tube of 100 mm length and 1.5 mm thickness is electromagnetically expanded using a 7 turn helical coil. Trials are taken for the different gaps between the coil and tube whereas discharge energy kept constant. 2D sequentially coupled numerical simulation carried out using COMSOL software. The tube displacement and the coupling factor obtained in the simulation showed good agreement with experimental observations. The coupling factor decreases with increase in the coil-tube gap. The Process efficiency and tube displacement are found to be improved exponentially with increasing in coupling factor. Considering various design aspects, coil and workpiece should be tightly coupled to achieve higher process efficiency.Item Influence of the Ambient Pressure on the Weld Quality for Magnetic Pulse Welded Sheet Joints(2018-05-15) Kümper, S.; Schumacher, E.; Böhm, S.This paper examines the effect of reduced ambient pressure during the welding process on the quality of magnetic pulse weld seams. For this purpose, a specifically developed vacuum chamber was applied, which enables a reproducible implementation. This, in turn, prepared the ground for a systematic examination of this promising process parameter. The tests focused on comparison of the weld seams realized with different currents and acceleration distances under atmospheric pressure and in the vacuum chamber. Here, both similar (EN AW-1050-H14) and dissimilar material combinations were considered (EN AW-1050A-H14 + S235JR; EN-AW 6016-T6 + DC04). The evaluation criteria for the quality of the welds were the tensile strength of the joint and the size of the weld seam.Item Application of Electromagnetic Forming as a Light-Weight Manufacturing Method for Large-Scale Sheet Metal Parts(2018-05-14) Lai, Zhipeng; Cao, Quanliang; Han, Xiaotao; Liu, Ning; Chen, Meng; Li, Xiaoxiang; Huang, Yujie; Chen, Qi; Li, LiangElectromagnetic forming (EMF), due to its advantages of light-equipment, single-side die, improved formability, reduced wrinkling, lower spring-back, and so on, is high potential for shaping large sheet metal parts in aviation and aerospace industries, which are generally relative expensive and difficult to be formed with conventional process. By exploiting the potential benefits of EMF, the required forming cost can be reduced, and the forming quality can be improved. Until now, however, the EMF of large sheet metal is still under-developed, which is highly attributed to the limited forming capability of the present equipment and the lack of a systematic design methodology for the process. In recently, we developed an EMF process that capable of shaping large sheet metal parts with light-weight equipment, and has successfully applied this process for manufacturing ellipsoid shaped aluminium alloy parts with 1378 mm diameter. To realize the light-weight of the proposed process, two newly–developed devices are highlighted. In this paper, the forming performance of the process are experimentally evaluated for AA5083 and AA2219 sheet workpieces, in terms of die fittability, thickness distribution, and radial material flow distribution. Furthermore, the comparisons of the proposed process with several other related forming processes are conducted to identify the advantages of the proposed process.Item Applications of Electromagnetic Forming Technology at the Wuhan National High Magnetic Field Center(2018-05-14) Li, Liang; Han, Xiaotao; Cao, Quangliang; Lai, Zhipeng; Deng, Fangxiong; Huang, Yuje; Liu, Ning; Chen, Meng; Li, Xiaoxiang; Chen, QiThe research of the electromagnetic forming (EMF) technology at the Wuhan National High Magnetic Field Center (WHMFC) has focused on designing electromagnetic system for generating a more flex-ible and strong Lorentz forces acting on workpieces, and then expanding the applications of EMF technology to solve current problems in forming large-scale and complex components. In this paper, we will sum up the latest progress of EMF technology at the WHMFC in detail according to recently reported works.Item A computational model for magnetic pulse forming processes – Application to a test case and sensitivity to dynamic material behaviour(2018-05-14) Bay, F.; Alves, J.This paper aims at presenting an efficient computational tool for magnetic pulse forming processes. This too - based on the coupling between the FORGE® thermomechanical solver and an electromagnetic module - is then applied to investigating a test case provided by the I2FG Group for benchmarking purposes. Comparisons carried out between the results obtained using a quasi-static constitutive law with one taking into account the dynamic behaviour of the material emphasize the sensitivity to dynamic material behaviour – and thus the need for carrying out material behaviour identification for strain rates close to the ones experiences by the material in such processes.Item Effect of Eccentric Field-shaper on Electromagnetic Crimping of Terminal Wire Interconnections(2018-05-15) Rajak, Ashish K.; Kumar, Ramesh; Kore, Sachin D.With the increase in losses in electric power transmission in crimped terminal-wire interconnections, due to improper crimping using conventional crimping process, it is essential to find a more efficient crimping technique. Some crucial challenges in conventional terminal-wire crimping process are spring back of terminal on tool relaxation, non-uniform terminal deformation due to tool-terminal contact process, flash out of material, voids between the wire strands etc. To overcome these problems Electromagnetic crimping process is found to be a most suitable technique. In this work, an eccentric geometry field-shaper is used for electromagnetic crimping of aluminium terminal over the aluminium wires which hasn’t been used yet in this field. Numerical simulations were carried out using LSDYNATM Electromagnetic module software. Results like current density, magnetic field, Lorentz force, and terminal deformation were discussed. The results from the numerical simulations were used for carrying out experiments. The validation was carried out using terminal deformation and terminal-wire contact length. The result of the work will be useful for electromagnetic crimping, welding and cladding process for similar applications.Item Consideration of the Magnetic Field Penetration through the Blank Wall in the Processes of Pulse-Magnetic Forming(2018-05-14) Karpukhin, V. F.; Chernikov, D.The results of the investigation of the effect of the magnetic field penetration through a blank wall on the necessary parameters of the pulse-magnetic forming are presented in this paper. The purpose of the work is to determine the permissible scope of engineering techniques for calculating the processes of pulse-magnetic forming of thin-walled parts. Process studies include conducting experiments, calculating by engineering methods and computer simulation of the process using LS-DYNA. As a result of the research it has been established that the engineering technique allows calculating the processes with sufficient accuracy at a blank thickness exceeding the value of the penetration depth of the pulse magnetic field into the blank material.Item On Process, Structure, Property Relationships in Impact Welding of Aluminum 6061 and Steel 4130(2018-05-15) Mao, Y.; Gupta, V.; Ufferman, B.; Vivek, A.; Choi, K. S.; Sun, X.; Daehn, G. S.Vaporizing Foil Actuator Welding process was used to weld 1mm thick aluminum alloy 6061 sheet to 3.2 mm thick 4130 grade steel plate. Temporal evolution of the flyer sheet velocity was recorded at four locations on the flyer sheet using photonic Doppler velocimetry. The welded samples were subjected to mechanical and microstructural characterization. Although the welded interface did not show a very wavy characteristic, the welds had substantial strength. Welds made with a softer temper, T4 alloy were found to be stronger than the one created with a harder, T6 temper alloy. A coupled Lagrangian-Eulerian numerical framework was also utilized to predict the structure of the interface based on the measured velocity profile. The model also depicted absence of large waves although the jetting phenomenon was observed, thereby providing insight into necessary conditions for impact welding.Item Numerical Simulation of Electrohydraulic Forming of Aluminium Alloy Tubes(2018-05-14) Zheng, Q. L.; Yu, H. P.Electrohydraulic forming has the advantages in improving formability and deformation precision of the workpiece, so it is concerned and applied in the plastic deformation for high precision parts, which are made of sheet or tube and difficult to form by traditional methods. However, electrohydraulic forming is based on a coupled effect of gaseous, liquid, and solid media and materials, and its states cannot be identified by experiments alone. Therefore, this paper takes the local bulging deformation behaviour of 5052 aluminium alloy tubes as the research object, used FEM software ANSYS/LS-DYNA to establish the numerical simulation model, and studied the plastic deformation behaviour of tubes under the action of shockwave load during electrohydraulic forming.Item Molecular Dynamics Modeling of Atomic Diffusion Across Fe-Al Magnetic-pulse-welding Interface(2018-05-15) Fan, Zhisong; Yu, Haiping; Deng, Jianghua; Li, ChunfengIn the present study, a molecular dynamic model has been developed for simulating of atomic diffusion behaviour in the Al-Fe system during the magnetic pulse welding process. Our simulations predict the structural evolution of the interfacial region. And the thickness of diffusion layer was studied. The atomic diffusion features at the bonding interface were investigated in detail. Furthermore, the concentration distribution of the elements across the diffusion layer was also presented in this paper. To verify the simulation results, relevant verification experiments were also carried out. The simulation results show a good correspondence with the experiments.Item Development of Numerical Simulation Model and Formability Evaluation for Electrohydraulic Forming Process(2018-05-14) Woo, M. A.; Song, W. J.; Kang, B. S.; Kim, J.In the automotive industry, the consumption of advanced high strength steels and aluminium alloys is increased to reduce the weight of automotive parts. However, because these materials have lower formability, it is not easy to deform these in the general forming process. Therefore, high speed forming processes are introduced such as electrohydraulic forming, electromagnetic forming and explosive forming. High speed forming is a process that deforms a material at a speed of more than 100 m/s. This paper describes the electrohydraulic forming (EHF) process. EHF is high strain rate forming process based on the electric discharge in the fluid. This process can improve the formability of the material due to the high strain rate of 103 ~ 104 s-1 and it can reduce the experimental cost by using only one-sided rigid tool. In this study, numerical model of EHF was developed in LS-DYNA commercial program and it showed that the material could be deformed by electric energy input inside the fluid. In addition, forming limit diagram (FLD) at high strain rate condition was obtained from M-K theory as criteria of formability evaluation and it was applied to the results of numerical simulation. As a result, it was predicted that the material has no cracks or wrinkles at a given energy input.