WHAT IS EXPLOSIVE FORMING PROCESS

The metal forming involves the detonation of an explosive charge, causing

a shock wave and a large momentum in the water, the expansion of
detonation gases, and the subsequent interaction with the metal plate.
A metal plate is clamped into a mould, and then immersed in a water
basin.
The energy releasing upon explosion of high explosive substance acts
directly or through a conductive medium on a metal plate and deform it to
fit the die profile.
Usually, explosive forming is done with the explosive charge in water, at a
certain stand-off distance of the part to be formed
The charge used is very small, but is capable of exerting tremendous
forces on the work piece.
In Explosive Forming chemical energy from the explosives is used to
generate shock waves through a medium (mostly water), which are
directed to deform the work piece at very high velocities.
The shock waves act as a punch.
Explosive Forming is also known as HERF (High Energy Rate Forming)
Explosive Forming Operations can be divided into two groups, depending on the
position of the explosive charge relative to the work piece.
Standoff Method

In this method, the explosive charge is located at some predetermined

distance from the work piece and the energy is transmitted through an
intervening medium like air, oil, or water.

Peak pressure at the work piece may range from a few thousand psi
(pounds/inch2) to several hundred thousand psi depending on the
parameters of the operation.

 Contact Method

In this method, the explosive charge is held in direct contact with the
work piece while the detonation is initiated.

The detonation produces interface pressures on the surface of the metal

up to several million psi (35000 MPa).

WORKING OF E.F.P
The system used for Standoff operation consists of following parts: 1)

An explosive charge

2)

An energy transmitted medium

3)

A die assembly

4)

The work piece.

E F P Schematic Diagram

Figure 1 shows an arrangement of Standoff Explosive forming operation.

The die assembly is put together on the bottom of the tank. Work piece is
placed on the die and blank holder placed above.
A vacuum is then created in the die cavity. The explosive charge is placed
in position over the centre of the work piece. The explosive charge is
suspended over the blank at a predetermined distance (known as standoff
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 work piece, the metal is
displaced into the die cavity.
EXPLOSIVES USED

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).
The type of charge, its location, method and place of its initiating determine
the pressure area of a sheet metal being deformed.
Most distributed types of charges are:
concentrated charge (generally spherical),
linear (detonating cable),
adjustable charge.
Explosives are divide into two classes;
Low Explosives in which the ammunition burns rapidly rather than
exploding, hence pressure build up is not large,
High Explosive which have a high rate of reaction with a large pressure
build up.
Features of Low and High Explosives
PROPERTY

HIGH EXPLOSIVE

LOW EXPLOSIVE

METHOD OF INITIATION

Primary HE-ignition, spark,

flame or impact

Ignition

Secondary HE-detonator , or
detonator and booster
combination
CONVERSION TIME

Microseconds

Milliseconds

PRESSURE

Upto 4,000,000 psi

Upto 40,000 psi

APPLICATIONS OF EXPLOSIVE FORMING

Explosive forming is applicable for the following materials:

Materials; all metals, including:

Titanium alloys (CP, Ti6Al4V, Ti6-2-4-2-, Ti-B21S, etc.)

Nickel alloys (718, 625, Hastelloy-X, etc.)

Aluminum alloys (e.g. 2024, 7075, 6xxx, 5xxx, etc.)

(Stainless) Steels

Special, extremely strong or brittle alloys, e.g. ODS alloy

PM1000

Characteristics
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.
Difficulties in forming
Heat treatments for metal is required after Explosive forming.
Limitations in pressing capacity
For Hot forming : costly tooling ; thinning; Alfa case removal(Ti)
Forgings :long lead times ; expensive
DISADVANTAGES
Explosive forming in basins has a number of disadvantages that prevent
its wide use:
a.

it is necessary each time either to lower a die weighing many tons into
the water or to evacuate the water from the basin and then refill it;

b. ground tremors and the spillage of water owing to the force of the
explosion make explosion forming in buildings difficult and usually make it
necessary to carry it out at open-air sites.
Basinless explosive forming, which is carried out in mobile or stationary
chambers, does not suffer from these disadvantages; there is water only
between the explosive charge and the blank, and the remainder of the
reinforced chamber is filled with air, which significantly reduces the shock
wave.