Abstract
The primary goal of this work is to understand the deformation behavior of an aluminum alloy (Al) workpiece by using a rapid compression machine (RCM). The primary novelty in this work is that this is the first study on sheet metal forming using RCM. Numerical simulation and experimental results are in excellent agreement, e.g., the dome-shape, the maximum height, the final outer diameter, and the thickness distribution of the deformed workpiece. We demonstrate that the maximum deformation height grows linearly with the peak pressure with an intercept tending to zero. The proposed linear relationship can be effectively used for designing new components for a specific application. Moreover, the proposed numerical model was competent in reproducing the experimental results of damage initiation and evolution in case of high peak pressure as well as the initial misalignment of the workpiece. The results of this investigation revealed that a rapid compression machine can be utilized efficiently for the controlled forming of complex shapes of metal sheets.
Highlights
The need for manufacturing large and extraordinarily complex parts leads to the development of unconventional techniques
Actual pressure profiles recorded from the experiments are crucial, and one has to consider these profiles for the numerical simulations
The numerical method and experimental results are in excellent agreement, e.g., the dome-shape, the maximum height, the final outer diameter, and the thickness distribution of the deformed workpiece
Summary
The need for manufacturing large and extraordinarily complex parts leads to the development of unconventional techniques. The classic machining of some essential components for the advanced industry limits the development of sectors such as aviation, automotive, defense, or art [1,2,3]. Sheet-metal forming by explosion addresses several crucial points for industrial applications. Explosive forming is applicable to small to large structures, a wide range of materials, complex shapes that are non-accessible by classical machining tools, and it is cost-effective [1,4]. In this process, an explosion is used as an energy source. One of the cheapest sources of energy is the chemical energy obtained by the fast ignition of a reactive mixture
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