An Experimental Study: Improved Electrohydraulic Forming Efficiency through Wire-Free Discharge
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Date
2025-08-26
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Abstract
This experimental research proposes improved electrohydraulic forming (EHF) methods to
overcome the limitations of traditional high-speed forming and deep-drawing processes.
EHF uses a working fluid to generate forming force, which lasts longer than in
electromagnetic or explosive forming, allowing precise shape control. However,
conventional EHF requires fastening wires and draining/refilling the working fluid for each
experiment, resulting in long preparation times and inconsistent forming due to variation in
wire position. To address these issues, two new methods ‘wire-cross EHF’ and ‘wire-free
EHF’ were introduced and tested using a free-bulging die and 0.5 t STS430 specimens.
Forming distribution was analysed by comparing forming force, forming height, and
preparation time. The wire-free EHF showed lower initial forming force but achieved
comparable forming height through consecutive experiments. It also demonstrated high
consistency and reduced total experiment time by 4.72 times compared to the conventional
EHF, which suffered from increased wire length during twisting, leading to variations in
forming height and forming distribution. Overall, the wire-free EHF proved most effective
in achieving consistent forming results with significantly reduced preparation time, making
it a promising approach for efficient EHF process.
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Keywords
Free forming, Electrode, Hydroforming
Subjects based on RSWK
Hydroumformen, Elektrode, Experiment