UNIT IV

SHEET METAL FORMING &

UNCONVENTIONAL FORMING PROCESS
HIGH ENERGY RATE FORMING
PROCESS [HERF ]
It is a process that form products at very high velocities and
extremely high pressure
 Large amount of energy is applied for a very short
interval of time.
High particle velocities are produced in contrast with
conventional forming process. The velocity of deformation is
also very large and hence these are also called High Velocity
Forming (HVF) processes.
HERF process used short burst of energy that is transmitted
to the part surface through a medium (water/air).
The resulting force or shockwave acts to force the part into a
die cavity that has the desired shape of finished product.
Materials being formed beyond their usual limits and
maintain excellent dimensional control.
 High energy required for small interval time.
Many metals tend to deform more rapidly under extra fast
application of load which make these processes useful to form
large size parts out of these most metals including those which
are difficult to form.
Material that are difficult to form in conventional methods
due to spring back effect will undergo large plastic deformation
with almost no spring back effect when HERF is used.
Advantages of HERF Processes
Production rates are higher, as parts are made at a rapid rate and
thus these process are also called high velocity forming process.
Die costs are relatively lower.
it is possible to form most metals including difficult to form
metals.
No or minimum spring back effect on the material after the
process.
Production cost is low as power hammer (or press) is eliminated
in the process.
Complex shapes / profiles can be made much easily, as compared
to conventional forming.
 Suitable for a range of production volume such as small
numbers, batches or mass production.

Limitations:
Not suitable to highly brittle materials.
Source of energy (chemical explosive or electrical) must be
handled carefully.
Highly skilled personnel are required from design to execution.
Dies need to be much bigger to withstand high energy rates and
shocks and to prevent cracking.
Applications:
In ship building to form large plates / parts (up to 25 mm
thick).
Bending thick tubes/ pipes (up to 25 mm thick).
Radar dish
space applications
TYPES OF HERF PROCESSES
1. EXPLOSIVE FORMING
2. ELECTRO HYDRAULIC FORMING
3. MAGNETIC PULSE FORMING