FORMING
PROBLEM-1(Explosive
Forming)
SOLUTION
=tan-1(
=45
= (1-cos45)=0.14644180=26.36
PROBLEM-2(Explosive
Forming)
Q. Calculate the efficiency of a explosive
forming process under water.
Assume 3 kg for the weight of moving water
front(w) and an impact velocity(v) of 200
m/sec. Specific energy content of explosive
is 3103 KJ/kg. Mass of average charge 0.1
kg
Solution:Given Data:
Weight of the moving water front,(w)=3 kg
Impact Velocity,(v)=200 m/sec
Specific energy content of explosive,=3103 KJ/kg
Mass of an average charge =0.1 kg
PROBLEM-3(Explosive
Forming)
Q. A charge of TNT weighing 10 N is used in
an unconfined explosive forming operation.
Plot the peak pressure over the work surface
with stand off distance.
Ans.
With water as the transmitting medium, the
peak pressure p obtained is given by
p=CWn/3D-n N/mm2
Where
Peak pressure
140000
120000
100000
80000
60000
40000
20000
0
0
PROBLEM-4(Explosive
Forming)
Q.
Calculate
the
quantity
of
the
explosiverequired for forming of an ultra-thin
wall steel decorating spherehaving diameter
2000mm and thickness 3mm.The material is
Q235 steel sheet.
Take
KN,the coefficient related to shell structure
and material property=4.51910-6
Q=
=
gm (ans)
PROBLEM-5(Explosive
Forming)
Q. Calculate the deformation energy of the
shellof metallic decorating sphere having 10
number of multiple sections during explosive
forming where strain energy of each tapered
section is 300 KJ and the strain energy of top
and bottom end sheet is 250KJ.
solution
Based
on Mises yield criterion, the total stain
Solution-
3500KJ
ELECTROMAGNETIC FORMING
=
Due to the inertia effect when deformation takes place at high
strain rates, a multiplying factor N of 2-10 is used to calculate
the magnetic pressure pm required to deform the tube. Therefore,
Pm=2tN /Do
PROBLEM-6
(Electromagnetic Forming)
Q. A brass tube(=300MPa) of 150mm outer
diameter and 2.5mm thickness is to be
formed using EMF. Calculate the magnetic
pressure required to deform it, using a
multiplying factor of 8 for high strain rates.
SOLUTION
Given data:
Yield strength of brass, =300MPa,
Outer diameter Do=150mm,
Thickness of tube t=2.5mm,
Multiplying factor, N=8
So,
Magnetic pressure
Pm=
=
=80 MPa
PROBLEM-7
(Electrohydraulic Forming)
Q. The charging voltage of an EHF machine is
16kV and the bank of capacitors is 120 F.
Calculate the machine capacity, given that
process efficiency is 20%.
SOLUTION
Given data:
Charge voltage(vc)=16kv,
Capacitance(cap.)=120F
a)Energy stored in charged capacitor(or machine
capacity)
E=0.5 cap.(Vc )2
=0.512010-6 (16103)2
=15360 J
=15.36 KJ
PROBLEM-8(Explosive
Forming)
Q. Calculate the peak pressure in water for
0.1 kg of TMT at a stand of 0.5m & comment
if this pressure is sufficiently high for forming
sheet metal.
a
3
W
Solution:
p k
Where,
p = peek pressure in Mpa
K = A constant dependent on the explosive
= 39 106 for TNT
p 39 10
6
0.1
0.5
= 34.88 MPa
1.5
PROBLEM-9
Q.A Thin-walled spherical shell is under internal
pressure, p. The shell is 0.5m in diameter and 2.5
mm thick. It is made of a perfectly plastic
material with a yield stress of 140 Mpa. Calculate
the pressure required to cause yielding of the
shell according to both yield criteria.
Solution
given,
shell diameter=0.5m
shell thickness=2.5mm
yield stress =140 Mpa
2tY
(2)(2.54 10 )(140)
2.8MPa
r
0.254
max min Y
or
1 0 Y
And
2 0 Y
Hence 1 2 140MPa
The pressure required is then
2tY (2)(2.54 10 3 )(140)
p
2.8MPa
r
0.254
( 1 2 ) ( 2 3 ) ( 3 1 ) 2Y
2
Or
0 22 12 2Y 2
1 2 Y
Hence
Therefore, the answer is the same, or
p=2.8MPa