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Springback Calibration of Sheet Metal Components Using Impulse Forming Methods

Woodward, Steven T.
http://rave.ohiolink.edu/etdc/view?acc_num=osu1306683543

Abstract Details

2011, Master of Science, Ohio State University, Materials Science and Engineering.
Impulse forming techniques are used to produce high strain rates to improve the formability of sheet metal. While these techniques are not commonly used in industry at the present time, research and testing has demonstrated enormous potential for new manufacturing processes incorporating these methods. The objective of this paper is to discuss the feasibility of the use of disposable actuators to eliminate springback in sheet metal components. Two impulse forming methods were investigated, electromagnetic forming and forming using an electrically driven expanding plasma, while three parts of increasing complexity were tested: a simple curved aluminum part, an aluminum aerospace part with a convex flange, and a high-strength steel structural u-channel part. The parts were pre-formed to a rough shape using traditional forming methods and then calibrated to the final desired shape using the impulse forming techniques. These processes work by transferring a large current through a thin aluminum actuator, generating a large controlled electromagnetic impulse in the case of electromagnetic forming or a high-pressure shockwave due to foil vaporization in the case of forming using electrically driven expanding plasma (fugitive foil forming). The test setup was optimized according to parameters such as actuator design, tool material, part stand-off distance, and capacitor discharge energy. In each case, the use of impulse forming methods resulted in significant springback reduction so that the parts were at or very near the desired specifications, demonstrating that these techniques can be used to improve current sheet metal production processes.
Glenn Daehn, PhD (Advisor)
Suresh Babu, PhD (Committee Member)
119 p.
Electromagnetics; Materials Science; Mechanical Engineering
electromagnetic forming (EMF); rubber pad forming; sheet metal forming; hybrid forming; disposable actuator; expanding plasma

Recommended Citations

Citations

  • Woodward, S. T. (2011). Springback Calibration of Sheet Metal Components Using Impulse Forming Methods [Master's thesis, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1306683543

    APA Style (7th edition)

  • Woodward, Steven. Springback Calibration of Sheet Metal Components Using Impulse Forming Methods. 2011. Ohio State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1306683543.

    MLA Style (8th edition)

  • Woodward, Steven. "Springback Calibration of Sheet Metal Components Using Impulse Forming Methods." Master's thesis, Ohio State University, 2011. http://rave.ohiolink.edu/etdc/view?acc_num=osu1306683543

    Chicago Manual of Style (17th edition)

osu1306683543
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© 2011, all rights reserved.
This open access ETD is published by The Ohio State University and OhioLINK.