Abstract
Electric-pulse triggered energetic materials forming (ETEF) is a high-speed manufacturing process, which utilizes the chemical energy released by energetic materials (EMs) triggered by underwater wire discharge to plastically shape metals. ETEF is not fully understood, particularly in research on the discharge characteristics of energetic materials triggered by metal wires and the deformation process of metal sheets. The above two problems were investigated in this paper using experimentation and numerical simulation. For the pulse discharge characteristics, the peak values of voltage and current were reduced during the triggering process of energetic materials, and the triggering energy consumption of energetic materials was quantified to be about 200 J. The matching parameters of different capacitor-voltage devices may be insensitive to triggering the energy release of energetic materials. The maximum major strain and thinning rate of the bulged specimen under ETEF conditions were significantly reduced when compared to the quasi-static specimen with the same bulging height, and the specimen’s deformation uniformity and strain distribution were improved. The simulation results showed that the addition of energetic materials significantly improved the plastic strain energy of the blank. The deformation of the blank in ETEF can be divided into two stages: the initial chemical energy action stage and the inertia action stage. The bulging height of sheet metal increased by nearly 301% in inertia action stage, accounting for 80% of the total deformation time, and the effective plastic strain distribution was more uniform.
Highlights
Electric-pulse triggered energetic materials forming (ETEF) is a high-speed manufacturing process, which utilizes the chemical energy released by energetic materials (EMs) triggered by underwater wire discharge to plastically shape metals
There are two reasons that may cause this phenomenon, one is that energetic materials are ignited, the other is that after wire explosion forms plasma, the nearby energetic materials are heated by thermal radiation to form a conductive layer, and the extra conductive layer increases the resistance of the discharge channel [20]
This phenomenon may be due to the fact that some energetic materials with high temperature are used as extra conductive substances, which accelerates the breakdown process of the wire vaporization discharge channel, resulting in a decrease in deposition energy
Summary
To improve the fuel efficiency and crashworthiness of automobiles, the use of high strength steel to develop lighter and safer cars has become a trend in the automobile industry. Based on the above problems, Yu et al [14] proposed a new high-velocity forming method, namely ETEF, which uses underwater metal wire electric explosion to ignite the chemical energy released by energetic materials to complete the deformation of the workpiece. Grinenko et al [16] conducted an experimental study on the underwater electric explosion of copper wire, and found that the efficiency of electrical energy deposition into the mechanical energy for the fluid flow was 25%, and the maximum pressure obtained at the boundary of discharge plasma channel was about 600MPa. the research on the discharge characteristics of energetic materials triggered by metal wires and the energy release level of energetic materials under different capacitance-voltage matching parameters is not clear, and the deformation process of workpieces in ETEF is not perfect. The deformation process of DP600 steel sheet in ETEF was studied by means of experiment and numerical analysis, such as strain distribution characteristics, deformation uniformity and dynamic deformation process
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