Electrohydraulic full-forward extrusion of small parts through high aspect ratio forming channels

Electrohydraulic incremental bulk forming was introduced as a novel micro part forming technology. Forming of parts from different materials and different initial diameter values was investigated in single-stage full-forward extrusion in recent work. In this paper, multi-stage extrusion in high aspect ratio forming channels is presented. Thereby, the aspect ratio of forming channel is high, when the channel length is much higher than the channel diameter and formed part length. Analytical and experimental investigations are carried out to correlate the supplied and required energy for extrusion. Experiments were made using an optical access made of sapphire as part of the extrusion channel to measure the position during forming increments. The influence of channel depth and curvature as well as of fluctuations in the transmitting media on the energy transmission to the formed EN AW-6061 aluminum alloy parts were found to be low

Electrohydraulic extrusion of spherical bronze (CuSn6) micro samples

Conventional material testing strategies are time and cost intensive. In this paper, a new method for contactless high-speed testing of spherical micro samples by an electrohydraulic punch is introduced. The punch transfers the punching force incrementally to extrude the samples stepwise in dies with high aspect ratios. The sample’s material behavior is characterized by analyzing the deformation behavior between the extrusion steps and at different forming stages

Effective electromagnetic forces in thin sheet metal specimen

Electromagnetic forming is mainly investigated for the macro world as the body forces in this high speed process are decreasing with the volume of the specimen. For micro metal sheets different effects are observed which make an analysis of the acting forces more difficult. Hence, the validity of process simulations for electromagnetic forming is still limited. In this research the effective electromagnetic force on thin EN AW-1050A (Al99.5) sheet metals is investigated by varying the loading energy EC, the ration sR between sheet thickness and skin depth, the sheets width b and the distance dC between passive tool and sheet metal

Effective electromagnetic forces in thin sheet metal specimen

Electromagnetic forming is mainly investigated for the macro world as the body forces in this high speed process are decreasing with the volume of the specimen. For micro metal sheets different effects are observed which make an analysis of the acting forces more difficult. Hence, the validity of process simulations for electromagnetic forming is still limited. In this research the effective electromagnetic force on thin EN AW-1050A (Al99.5) sheet metals is investigated by varying the loading energy EC, the ration sR between sheet thickness and skin depth, the sheets width b and the distance dC between passive tool and sheet metal