Concept of Smart Electrohydraulic Press for Impulse Sheet Forming
Electrohydraulic impulse sheet forming (EHF) method proved its high efficiency at pilot, small-batch, and middle-scale production conditions. As the latest achievement, multielectrode discharge blocks provide effective forming of the middle and large size sheet parts. However, wide application of EH...
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Інститут металофізики ім. Г.В. Курдюмова НАН України
2016
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| Назва видання: | Металлофизика и новейшие технологии |
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| Цитувати: | Concept of Smart Electrohydraulic Press for Impulse Sheet Forming / M.K. Knyazyev, Ch. Beerwald // Металлофизика и новейшие технологии. — 2016. — Т. 38, № 12. — С. 1669-1680. — Бібліогр.: 9 назв. — англ. |
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irk-123456789-1126422017-01-25T03:02:54Z Concept of Smart Electrohydraulic Press for Impulse Sheet Forming Knyazyev, M.K. Beerwald, Ch. Физика прочности и пластичности Electrohydraulic impulse sheet forming (EHF) method proved its high efficiency at pilot, small-batch, and middle-scale production conditions. As the latest achievement, multielectrode discharge blocks provide effective forming of the middle and large size sheet parts. However, wide application of EHF technology in industry is limited mainly by two problems: instability of impulse pressure fields and lack of literature as well as skilled EHF specialists. Now the problem of instability is solved by a qualified EHF specialist with intermediate disclosing of tooling, inspection of intermediate shapes of blank, making corrections in loading diagram (electrodes’ connections), and setting of new level of discharge energies. New approach to this problem includes solutions based on intellectual computer numerical control of EHF equipment: monitoring of intermediate shape of sheet blank after each discharge and making corrections of loading parameters for the next discharge till the final shape of part. Intermediate shape can be determined by measurements with special sensors built in a die in characteristic places (points). Another subsystem should analyse position of several principal segments of blank, compare them with total strategy of forming procedure for a definite type of sheet part, reveal those places, which need higher pressure to harmonise forming process, and give this information to the subsystem controlling a multicircuit current generator for optimised configuration of activated electrodes and energy level, thus, determining new pressure loading diagram for the next discharge. Now, the tests for blank shape measuring system are planned to solve this principal problem for realisation of the submitted concept. In addition, principal design solutions for multicircuit current generator with special unit for reconnections of electrodes are in work. Спосіб електрогідравлічного імпульсного листового штампування (ЕГШ) довів високу ефективність в умовах пробного, дрібносерійного і середньосерійного виробництва. Новітнє досягнення, – багатоелектродні розрядні блоки, – забезпечує ефективне штампування листових деталів середніх і великих розмірів. Однак широке застосування технології ЕГШ у промисловості обмежується в основному двома проблемами: нестабільністю імпульсних полів тиску і недостачею літератури та кваліфікованих спеціялістів у галузі ЕГШ. У теперішній час проблема нестабільности розв’язується кваліфікованим спеціялістом ЕГШ шляхом розкриття оснащення, оглядом проміжних форм заготованки, внесенням корекцій у схему навантаження (схеми підключення електрод) і встановленням нових рівнів енергії розрядів. Новий підхід до розв’язання цієї проблеми передбачає рішення, які ґрунтуються на використанні інтелектуальної комп’ютерної числової системи керування обладнанням ЕГШ: виявлення проміжної форми листової заготованки після кожного розряду і внесення корекцій у параметри навантаження для кожного наступного розряду до одержання кінцевої форми деталю. Проміжну форму можна визначити шляхом міряння спеціяльними давачами, яких вбудовано в штамп у характерних місцях (точках). Друга підсистема має аналізувати положення декількох принципових ділянок заготованки, порівнювати їх із загальною стратегією процесу штампування для певного типу деталів, виявляти ті ділянки, які потребують більш високий тиск для гармонізації процесу формоутворення, і надавати цю інформацію в підсистеми, які керують багатоконтурним ґенератором струмів для утворення оптимізованої конфіґурації підключених електрод і рівня енергії, таким чином, визначаючи нову схему навантаження для наступного розряду. У теперішній час заплановано досліди по системі міряння форми заготованки для розв’язання цієї принципової проблеми в реалізації запропонованої концепції. Також опрацьовуються принципові конструкторські рішення для багатоконтурного ґенератора імпульсних струмів зі спеціяльним пристроєм для перемикання електрод. Способ электрогидравлической импульсной листовой штамповки (ЭГШ) доказал высокую эффективность в условиях пробного, мелкосерийного и среднесерийного производства. Новейшее достижение, – многоэлектродные разрядные блоки, – обеспечивает эффективную штамповку листовых деталей средних и больших размеров. Однако широкое применение технологии ЭГШ в промышленности ограничивается в основном двумя проблемами: нестабильностью импульсных полей давления и недостатком литературы и квалифицированных специалистов в области ЭГШ. В настоящее время проблема нестабильности решается квалифицированным специалистом ЭГШ путём раскрытия оснастки, осмотром промежуточных форм заготовки, внесением коррекций в схему нагружения (схемы подсоединения электродов) и установлением новых уровней энергии разрядов. Новый подход к решению этой проблемы предусматривает решения, основанные на применении интеллектуальной компьютерной числовой системы управления оборудованием ЭГШ: определение промежуточной формы листовой заготовки после каждого разряда и внесение коррекций в параметры нагружения для каждого последующего разряда до получения окончательной формы детали. Промежуточную форму можно определить путём измерения специальными датчиками, встроенными в штамп в характерных местах (точках). Вторая подсистема должна анализировать положение нескольких принципиальных участков заготовки, сравнивать их с общей стратегией процесса штамповки для определённого типа деталей, выявлять те участки, которые нуждаются в более высоком давлении для гармонизации процесса формообразования, и подавать эту информацию в подсистемы, которые управляют многоконтурным генератором токов для создания оптимизированной конфигурации подключённых электродов и уровня энергии, таким образом, определяя новую схему нагружения для следующего разряда. В настоящее время запланированы опыты по системе измерения формы заготовки для решения этой принципиальной проблемы в реализации предлагаемой концепции. Также прорабатываются принципиальные конструкторские решения для многоконтурного генератора импульсных токов со специальным устройством для переключения электродов. 2016 Article Concept of Smart Electrohydraulic Press for Impulse Sheet Forming / M.K. Knyazyev, Ch. Beerwald // Металлофизика и новейшие технологии. — 2016. — Т. 38, № 12. — С. 1669-1680. — Бібліогр.: 9 назв. — англ. 1024-1809 DOI: 10.15407/mfint.38.12.1669 PACS: 07.07.Tw, 07.10.Pz, 07.35.+k, 52.80.Wq, 62.50.-p, 62.50.Ef, 81.20.Hy, 81.40.Vw http://dspace.nbuv.gov.ua/handle/123456789/112642 en Металлофизика и новейшие технологии Інститут металофізики ім. Г.В. Курдюмова НАН України |
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Физика прочности и пластичности Физика прочности и пластичности |
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Физика прочности и пластичности Физика прочности и пластичности Knyazyev, M.K. Beerwald, Ch. Concept of Smart Electrohydraulic Press for Impulse Sheet Forming Металлофизика и новейшие технологии |
| description |
Electrohydraulic impulse sheet forming (EHF) method proved its high efficiency at pilot, small-batch, and middle-scale production conditions. As the latest achievement, multielectrode discharge blocks provide effective forming of the middle and large size sheet parts. However, wide application of EHF technology in industry is limited mainly by two problems: instability of impulse pressure fields and lack of literature as well as skilled EHF specialists. Now the problem of instability is solved by a qualified EHF specialist with intermediate disclosing of tooling, inspection of intermediate shapes of blank, making corrections in loading diagram (electrodes’ connections), and setting of new level of discharge energies. New approach to this problem includes solutions based on intellectual computer numerical control of EHF equipment: monitoring of intermediate shape of sheet blank after each discharge and making corrections of loading parameters for the next discharge till the final shape of part. Intermediate shape can be determined by measurements with special sensors built in a die in characteristic places (points). Another subsystem should analyse position of several principal segments of blank, compare them with total strategy of forming procedure for a definite type of sheet part, reveal those places, which need higher pressure to harmonise forming process, and give this information to the subsystem controlling a multicircuit current generator for optimised configuration of activated electrodes and energy level, thus, determining new pressure loading diagram for the next discharge. Now, the tests for blank shape measuring system are planned to solve this principal problem for realisation of the submitted concept. In addition, principal design solutions for multicircuit current generator with special unit for reconnections of electrodes are in work. |
| format |
Article |
| author |
Knyazyev, M.K. Beerwald, Ch. |
| author_facet |
Knyazyev, M.K. Beerwald, Ch. |
| author_sort |
Knyazyev, M.K. |
| title |
Concept of Smart Electrohydraulic Press for Impulse Sheet Forming |
| title_short |
Concept of Smart Electrohydraulic Press for Impulse Sheet Forming |
| title_full |
Concept of Smart Electrohydraulic Press for Impulse Sheet Forming |
| title_fullStr |
Concept of Smart Electrohydraulic Press for Impulse Sheet Forming |
| title_full_unstemmed |
Concept of Smart Electrohydraulic Press for Impulse Sheet Forming |
| title_sort |
concept of smart electrohydraulic press for impulse sheet forming |
| publisher |
Інститут металофізики ім. Г.В. Курдюмова НАН України |
| publishDate |
2016 |
| topic_facet |
Физика прочности и пластичности |
| url |
http://dspace.nbuv.gov.ua/handle/123456789/112642 |
| citation_txt |
Concept of Smart Electrohydraulic Press for Impulse Sheet Forming / M.K. Knyazyev, Ch. Beerwald // Металлофизика и новейшие технологии. — 2016. — Т. 38, № 12. — С. 1669-1680. — Бібліогр.: 9 назв. — англ. |
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Металлофизика и новейшие технологии |
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1669
PACS numbers:07.07.Tw, 07.10.Pz,07.35.+k,52.80.Wq,62.50.-p,62.50.Ef,81.20.Hy, 81.40.Vw
Concept of Smart Electrohydraulic Press for Impulse Sheet
Forming
M. K. Knyazyev and Ch. Beerwald*
National Aerospace University ‘Kharkiv Aviation Institute’,
Department of Aircraft Engine Technology,
17 Chkalov Str.,
61070 Kharkiv, Ukraine,
*Poynting GmbH,
65 Alte Str.,
44143 Dortmund, Germany
Electrohydraulic impulse sheet forming (EHF) method proved its high effi-
ciency at pilot, small-batch, and middle-scale production conditions. As the
latest achievement, multielectrode discharge blocks provide effective form-
ing of the middle and large size sheet parts. However, wide application of
EHF technology in industry is limited mainly by two problems: instability of
impulse pressure fields and lack of literature as well as skilled EHF special-
ists. Now the problem of instability is solved by a qualified EHF specialist
with intermediate disclosing of tooling, inspection of intermediate shapes of
blank, making corrections in loading diagram (electrodes’ connections), and
setting of new level of discharge energies. New approach to this problem in-
cludes solutions based on intellectual computer numerical control of EHF
equipment: monitoring of intermediate shape of sheet blank after each dis-
charge and making corrections of loading parameters for the next discharge
till the final shape of part. Intermediate shape can be determined by meas-
urements with special sensors built in a die in characteristic places (points).
Another subsystem should analyse position of several principal segments of
blank, compare them with total strategy of forming procedure for a definite
type of sheet part, reveal those places, which need higher pressure to harmo-
nise forming process, and give this information to the subsystem controlling
a multicircuit current generator for optimised configuration of activated
Corresponding author: Mykhaylo Klymovych Knyazyev
E-mail: knyazyev@yandex.ua
Please cite this article as: M. K. Knyazyev and Ch. Beerwald, Concept of Smart
Electrohydraulic Press for Impulse Sheet Forming, Metallofiz. Noveishie Tekhnol., 38,
No. 12: 1669—1680 (2016), DOI: 10.15407/mfint.38.12.1669.
Металлофиз. новейшие технол. / Metallofiz. Noveishie Tekhnol.
2016, т. 38, № 12, сс. 1669—1680 / DOI: 10.15407/mfint.38.12.1669
Оттиски доступны непосредственно от издателя
Фотокопирование разрешено только
в соответствии с лицензией
2016 ИМФ (Институт металлофизики
им. Г. В. Курдюмова НАН Украины)
Напечатано в Украине.
1670 M. K. KNYAZYEV and Ch. BEERWALD
electrodes and energy level, thus, determining new pressure loading diagram
for the next discharge. Now, the tests for blank shape measuring system are
planned to solve this principal problem for realisation of the submitted con-
cept. In addition, principal design solutions for multicircuit current genera-
tor with special unit for reconnections of electrodes are in work.
Key words: press, computer numerical control, electrohydraulic impulse
forming.
Спосіб електрогідравлічного імпульсного листового штампування (ЕГШ)
довів високу ефективність в умовах пробного, дрібносерійного і середньо-
серійного виробництва. Новітнє досягнення, – багатоелектродні розряд-
ні блоки, – забезпечує ефективне штампування листових деталів серед-
ніх і великих розмірів. Однак широке застосування технології ЕГШ у
промисловості обмежується в основному двома проблемами: нестабільніс-
тю імпульсних полів тиску і недостачею літератури та кваліфікованих
спеціялістів у галузі ЕГШ. У теперішній час проблема нестабільности
розв’язується кваліфікованим спеціялістом ЕГШ шляхом розкриття
оснащення, оглядом проміжних форм заготованки, внесенням корекцій у
схему навантаження (схеми підключення електрод) і встановленням но-
вих рівнів енергії розрядів. Новий підхід до розв’язання цієї проблеми
передбачає рішення, які ґрунтуються на використанні інтелектуальної
комп’ютерної числової системи керування обладнанням ЕГШ: виявлення
проміжної форми листової заготованки після кожного розряду і внесення
корекцій у параметри навантаження для кожного наступного розряду до
одержання кінцевої форми деталю. Проміжну форму можна визначити
шляхом міряння спеціяльними давачами, яких вбудовано в штамп у харак-
терних місцях (точках). Друга підсистема має аналізувати положення декі-
лькох принципових ділянок заготованки, порівнювати їх із загальною стра-
тегією процесу штампування для певного типу деталів, виявляти ті ділян-
ки, які потребують більш високий тиск для гармонізації процесу формоут-
ворення, і надавати цю інформацію в підсистеми, які керують багатоконту-
рним ґенератором струмів для утворення оптимізованої конфіґурації підк-
лючених електрод і рівня енергії, таким чином, визначаючи нову схему на-
вантаження для наступного розряду. У теперішній час заплановано досліди
по системі міряння форми заготованки для розв’язання цієї принципової
проблеми в реалізації запропонованої концепції. Також опрацьовуються
принципові конструкторські рішення для багатоконтурного ґенератора ім-
пульсних струмів зі спеціяльним пристроєм для перемикання електрод.
Ключові слова: прес, числове програмне керування, електрогідравлічне
імпульсне штампування.
Способ электрогидравлической импульсной листовой штамповки (ЭГШ)
доказал высокую эффективность в условиях пробного, мелкосерийного и
среднесерийного производства. Новейшее достижение, – многоэлек-
тродные разрядные блоки, – обеспечивает эффективную штамповку ли-
стовых деталей средних и больших размеров. Однако широкое примене-
ние технологии ЭГШ в промышленности ограничивается в основном дву-
мя проблемами: нестабильностью импульсных полей давления и недо-
SMART ELECTROHYDRAULIC PRESS FOR IMPULSE SHEET FORMING 1671
статком литературы и квалифицированных специалистов в области ЭГШ.
В настоящее время проблема нестабильности решается квалифицирован-
ным специалистом ЭГШ путём раскрытия оснастки, осмотром промежу-
точных форм заготовки, внесением коррекций в схему нагружения (схе-
мы подсоединения электродов) и установлением новых уровней энергии
разрядов. Новый подход к решению этой проблемы предусматривает ре-
шения, основанные на применении интеллектуальной компьютерной
числовой системы управления оборудованием ЭГШ: определение проме-
жуточной формы листовой заготовки после каждого разряда и внесение
коррекций в параметры нагружения для каждого последующего разряда
до получения окончательной формы детали. Промежуточную форму
можно определить путём измерения специальными датчиками, встроен-
ными в штамп в характерных местах (точках). Вторая подсистема должна
анализировать положение нескольких принципиальных участков заго-
товки, сравнивать их с общей стратегией процесса штамповки для опре-
делённого типа деталей, выявлять те участки, которые нуждаются в более
высоком давлении для гармонизации процесса формообразования, и по-
давать эту информацию в подсистемы, которые управляют многоконтур-
ным генератором токов для создания оптимизированной конфигурации
подключённых электродов и уровня энергии, таким образом, определяя
новую схему нагружения для следующего разряда. В настоящее время
запланированы опыты по системе измерения формы заготовки для реше-
ния этой принципиальной проблемы в реализации предлагаемой концеп-
ции. Также прорабатываются принципиальные конструкторские реше-
ния для многоконтурного генератора импульсных токов со специальным
устройством для переключения электродов.
Ключевые слова: пресс, числовое программное управление, электрогид-
равлическая импульсная штамповка.
(Received May 5, 2016)
1. INTRODUCTION
Variety of sheet metal parts in terms of geometry complexity and overall
dimensions, materials used, required quality parameters and production
rate accounts for wide range of sheet metal forming processes available
at the market. Among them, well-known and widely used methods like
roll forming or stamping as well as novel techniques like incremental
sheet forming (ISF), ford freeform fabrication technology (F3T), which
are developed to overcome the limitations of long-term used well-
known processes.
Focusing on complex 3D-shape structures, the most widely used
forming methods are stamping, hydroforming, rubber-pad forming
and superplastic forming. These conventional industrial sheet metal
forming processes have already reached high level of their maturity
and have clear application domains and limitations.
1672 M. K. KNYAZYEV and Ch. BEERWALD
For example, cold or hot stamping, being economically efficient pro-
cesses for large batch manufacturing, loose their advantages if the low
production volume or short-term order fulfilment are required. The
reasons are expensiveness of two-side tooling (i.e. punch and die set)
and long duration of tooling design, manufacturing and try-out.
Moreover, in case of complex parts, forming more than one two-side
tooling set is commonly required due to the forming process realisation
in several stages.
Hydroforming requires single rigid tool (die or punch), while anoth-
er one is fluid that forms metal into a die inside the pressurised cham-
ber. However, its wide application is limited due to complexity and ex-
pensiveness of the respective machinery. Hydroforming presses re-
quire thick-walled chambers able to withstand high static pressure of
up to 2000 bars with pressure-tight covers. High pressure is created by
complicated and energy intensive hydraulic system with pressure ampli-
fiers. In addition, this method is characterised by the uniform pressure
distribution along the workpiece surface that makes its application non-
efficient for complex 3D-shaped sheet parts with local elements.
Rubber-pad forming process having the same advantage of one-side
metal tooling uses elastic material (rubber or polyurethane) for shape
generation. This method is applicable for small- and middle-size sheet
parts under small- and middle-scale production, but its capabilities are
limited to shallow 3D shapes. Another drawback of rubber-pad form-
ing is an increased springback of the formed parts caused by the rela-
tively low pressure to the part and decreased pressure in local elements
due to high viscosity of rubber. Manufacturing of middle and large-
size sheet parts has low efficiency due to the necessity of large hydrau-
lic presses with high energy consumption.
Another alternative method for 3D-shapes’ manufacturing is a su-
perplastic forming by an inert gas (typically argon) under the high
temperature (500—600C). This process allows obtaining of super elon-
gations of sheet metal (up to 600—1000%), but it is characterised by
extremely high energy consumption and is applicable for limited range
of materials. Only ultrafine grain structures (1—2 m) has superplastic
capability, thus sheet materials have to be preliminary treated which
significantly increases process cost-efficiency. One more limitation is
caused by the uniform pressure field resulting in excessive thinning in
local 3D elements that reduces total part strength.
In comparison with the above-reviewed forming methods, the elec-
trohydraulic impulse sheet forming (EHF) method has advantages of
one-side die, improved formability and small springback due to high
speed of deformations, low material intensiveness of equipment, low
electric energy consumption per an item produced.
EHF method proved its high efficiency at pilot, small-batch and
middle-scale production conditions. The latest achievement–
SMART ELECTROHYDRAULIC PRESS FOR IMPULSE SHEET FORMING 1673
multielectrode discharge blocks–provide effective forming of middle
and large size sheet parts due to improved controllability of pressure
fields generated by large number of electrodes [1—3]. However, wide
application of EHF technology in industry is limited mainly by two
problems: instability of impulse pressure fields and lack of specialised
literature and skilled EHF specialists.
Instability is realized in two aspects: instability of pressure distri-
bution along sheet blank surface and low repeatability of pressure field
from one discharge to another. Long-term experience in EHF presses
usage allowed to reveal and analyse factors that cause instability of
sheet parts forming: instability of discharge electric parameters initi-
ated by high-voltage breakdown in a liquid, position instability of dis-
charge channel in a spark gap, shadow effects of electrodes, wear of
current rods and insulators of electrodes, changes in a sheet blank
shape during forming process, increases of work volume and distance
between spark gap and sheet blank with a blank shape progress, etc.
Now, the EHF problems are solved by a qualified EHF specialist with
intermediate disclosing of tooling, inspection of intermediate shapes
of blank, making corrections in loading diagram (electrodes connec-
tions) and setting of new level of discharged energies (by changing a
charged voltage and capacitance). Thus, pressure field and energy for
the next discharges are determined on the basis of experience and skill
of EHF specialist.
The purpose of this work is to develop new principal concept of EHF
press based on previous publications [4, 5] on intellectual control sys-
tem to overcome current limitations of EHF method for wide industri-
al application.
2. UP-TO-DATE REALISATION OF MULTIELECTRODE EHF
TECHNOLOGY
An idea of multielectrode discharge block (MEDB) application for elec-
trohydraulic forming was generated and patented by Prof. Yuri Cheba-
nov in 1983 in the National Aerospace University ‘KhAI’. Unlike tradi-
tionally used single electrode pair in a dome-shaped discharge chamber,
MEDB includes great number of closely positioned insulated electrodes
fixed in one solid plate. Another plate (called ‘discharge plate’) with
holes serves as common opposite-charged electrode for all insulated elec-
trodes. At the same time, holes serve as guiding nozzles for pressure im-
pulses (shockwaves), because each electrode is surrounded by the wall
of hole in discharge plate with opening directed to a sheet workpiece.
This small discharge volume for each electrode forms pressure impulse
directed to sheet workpiece and the wall protects insulated electrode
from action of other pressure impulses. Each electrode in this case has
to be served with individual high-voltage capacitors (discharge cir-
1674 M. K. KNYAZYEV and Ch. BEERWALD
cuit).
It was a revolutionary solution for improvement of EHF capabilities
by means of efficient control of generated impulse pressure field. This
efficient control is realised by means of activation of not all electrodes
available in MEDB, but only several of them. Simultaneous discharges
of optimally selected electrodes enable generation of non-uniform im-
pulse pressure field of optimal configuration that corresponds to the
specific geometry of the part to be produced. It means that impulse
pressure is concentrated in those areas of workpiece where maximum
deformation is required. Moreover, non-linear effects of several
shockwaves interaction significantly amplify pressure field intensity
and overall MEDB-based forming process efficiency.
MEDB concept feasibility was validated in the ‘KhAI’ Laboratory of
Electrohydraulic Forming. Demonstrated in the Figure 1 proof-of-
concept prototype UEHF-2 provides a possibility to use up to 22 active
electrodes that could be placed in 52 different positions. Maximum
number of active electrodes is defined by the number of discharge cir-
cuits of multicircuit pulse current generator available for connections.
During UEHF-2 prototype application, an optimal arrangement of
active electrodes either is determined experimentally or is based on the
previous experience accumulated, while electrodes positioning and
connection/activation are realised manually. Even at this low technol-
ogy readiness level, great potential of MEDB application was demon-
strated by successful production of complex 3D-sheet parts of middle
and large size made of different materials that are shown in the Fig. 2.
Experience in application of EHF presses based on MEDB design re-
vealed two problems that prevent wide usage of EHF technology in in-
dustry: instability of impulse pressure fields and lack of specialised
literature and skilled EHF specialists.
Fig. 1. General view of MEDB of UEHF-2 experimental installation and repre-
sentative scheme of possible electrode pairs arrangement [6] (positions
marked with ‘ ’ symbol are active on the MEDB photo).
SMART ELECTROHYDRAULIC PRESS FOR IMPULSE SHEET FORMING 1675
Instability is realised in two aspects: instability of pressure distri-
bution along sheet blank surface and low repeatability of pressure field
from one discharge to another. Long-term experience in MEDB design
usage allowed to reveal and analyse factors that cause instability of
sheet parts forming: instability of discharge electric parameters initi-
ated by high-voltage breakdown in a liquid, position instability of dis-
charge channel in a spark volume between two opposite electrodes,
shadow effects of electrodes, wear of current rods and insulators of
electrodes, changes in a sheet blank shape during forming process, in-
creases of work volume and distance between spark gap and sheet blank
with a blank shape progress, etc. All these factors result in unstable
formed shapes though configuration of activated electrodes is optimal.
Now, this problem is solved by high-skilled EHF specialist. He makes
periodical inspections of semi-formed sheet part after one or several dis-
charges in order to estimate rightness of forming process and to do cor-
rections in activated electrodes configuration and discharge energy level
for each activated electrode for the next forming step. In order to perform
inspections, EHF press operator should pour out ware from discharge
block, unclamp die, and move it to auxiliary position, i.e., each time for
inspection the disclosing of die is needed. Of course, these actions do take
long periods of time that significantly reduce EHF efficiency.
After inspections, the solutions for the next discharges are made on
basis of accumulated experience in MEDB application for manufacture
of complicated 3D shapes during several years. In addition, these solu-
tions are made at each of three stages of forming process: generation of
general shape, forming of smaller local elements and calibration. Un-
a b c
Fig. 2. Examples of complex sheet metal parts produced in UEHF-2 installa-
tion: torus-type semi-product made of 08kp steel (thickness 1.5 mm) in the die
made of the same steel [2] (a); box-type semi-product made of AMg6 high-
strength aluminium alloy (thickness – 2.0 mm) produced in the die presented
in Fig. 1 [6] (b); ‘pan’ semi-product made of 12Cr18Ni10Ti stainless steel
(thickness 0.8 mm) produced in Al—Zn die [7] (c).
1676 M. K. KNYAZYEV and Ch. BEERWALD
fortunately, this experience is not formalised and not described in spe-
cialised literature in sufficient volume yet.
Therefore, further implementation of novel EHF MEDB equipment
and processes should include solutions of these problems by modern
means with application computer-based technologies [8].
Demonstrated efficiency of MEDB-based EHF process in combination
with extensive capabilities of advanced simulation methods, sensing
techniques and control systems create a positive ground for renewal of
EHF process industrial application. Being developed at the new level,
the EHF process will be able to cope with current trends in mechanical
products design and stricter economic and ecological requirements.
3. CONCEPT OF SMART MULTIELECTRODE EHF PRESS
The purpose of new concept is to overcome current technical state-of-
the-art of EHF processes in terms of process automation and reliability
in parallel with achievement of high level of material and energy effi-
ciency for customised and small batch production of complex 3D sheet
metal parts. To reach these ambition targets, the overall concept con-
sists in the synergy of three innovative approaches:
— application of adaptive MEDB system instead of one pair of elec-
trodes; system adaptivity will ensure activation of optimal set of elec-
trodes that are pre-selected by the control system to generate optimal
multielectrode discharge and create shape-generating pressure field
that fits to the part geometry; it will increase EHF process efficiency
and reduce energy consumptions; innovative architecture of adaptive
MEDB system will make possible to realise sheet metal part forming
process in automated mode;
— integration of sensing capabilities into the one-side die to create an
innovative sensing die and realise continuous in-process monitoring of
workpiece shape, thus contributing to EHF process reliability and sup-
porting real-time process control and optimisation by the intellectual
control system;
— automation and real-time optimisation of sheet metal part forming
by smart control system to ensure EHF process efficiency, high quality
of sheet metal parts and minimum use of energy; control system opera-
tion will be based on application of advanced simulation models and
optimisation algorithm to define optimal multielectrode discharge to
be realised by adaptive MEDB system [9].
The listed principal solutions are depicted in a graphic form in the
Fig. 3. It is obvious that principal element of the proposed solution is a
sensing die, i.e., die equipped with sensors indicating positions of vari-
ous segments of a formed sheet blank. Coordinates of the sensors (xi, yi,
zi) along the die cavity will give data for plotting 3D models for inter-
mediate shapes after each multielectrode discharge and indicate com-
SMART ELECTROHYDRAULIC PRESS FOR IMPULSE SHEET FORMING 1677
pleteness of final shape formed (Fig. 3, signal processing module). This
is so-called feedback system giving information about actual shape of a
formed blank without opening of tooling and so making possible to do
reconnections in MEDB for activation of those electrodes needed for
improved pressure field at the next discharge. Correctness of 3D mod-
els depends on coordinates and quantity of sensors. The latter can be
estimated as 5 for simpler shapes and 30 and more for complicated
shapes with big number of small local elements characterised by small
radii. It should be noticed here that accuracy of detection of intermedi-
ate shapes at the first general forming stage will not be so high, be-
cause of small-area contact of sheet blank and die surface, but it is
enough to plot 3D model and do prediction for the discharge. Accuracy
of 3D models at the second (local forming) and the third (calibration)
stages will be high due to definite position of most blank elements con-
tacting with the die surface having exact geometric configuration. Us-
ing Human Machine Interface (HMI, Fig. 3), a press operator can ob-
serve progress of blank shapes from one discharge to another and check
correctness of forming procedure without opening of tooling, in com-
parison with present situation, when forming process should be
stopped, tooling should be opened in order to inspect intermediate or
final shape of blank.
Decisions on improvements in pressure field for the next discharge
are made in automatic mode by multielectrode discharge optimisation
module (Fig. 3) by generating commands for setting new configuration
of activated (connected) electrodes and new levels of charged voltage
and capacitance for each electrode connected to multicircuit high-
voltage (HV) pulse generator, thus determining a new level of energy
Fig. 3. General diagram of smart EHF press.
1678 M. K. KNYAZYEV and Ch. BEERWALD
discharged over a definite segment of sheet blank. The decisions are
made in such a manner to keep general forming strategy for a definite
type of shape (dome round, box, semi-torus, steeply curved half-pipe,
fairing, etc.) taking into account positions and dimensions of local ele-
ments. Therefore, the optimisation module should include database of
forming strategies for representative parts as well as for unusual in-
tricate shapes (Fig. 4). Optimisation module can include different pa-
rameters for optimisation: realisation of deep-drawing procedure,
stress distribution to avoid wrinkling, sheet thickness distribution to
ensure the same strength parameter, improvements of accuracy and
springback, etc.
Configurations of activated electrodes and levels of energy elec-
Fig. 4. Architecture of smart control system.
SMART ELECTROHYDRAULIC PRESS FOR IMPULSE SHEET FORMING 1679
trodes’ levels for the first discharge are initially determined from the
general forming strategy for a representative part. The next discharg-
es parameters are based on comparison of forming strategy steps (as-
signed intermediate shapes) and actual intermediate shapes. After the
forming of first part of definite geometry and material, its forming
procedure can be considered and remembered as a new optimised form-
ing strategy for this definite part. Further improvements in the strat-
egy are determined by wear of electrodes, variations in sheet material
properties and thickness, deviations of initial blank configuration and
its initial position relative to the die cavity, etc.
Development of forming strategies for database (Fig. 4) is based on
experience accumulated during long years of experimental EHF of 3D
shapes of representative types of parts and described in publications
and scientific reports. In addition, computer simulations of multielec-
trode EHF processes for typical and unusual shapes will be useful for
compiling the forming strategies for materials with different physical
and mechanical properties.
Output commands of smart control system are realised by adaptive
MEDB system before each multielectrode discharge. The control sys-
tem should also generate control commands for usual functions of EHF
press (not shown in Fig. 4): motions of die to work position and back,
filling of MEDB with water and pouring it out, air evacuation, etc.
4. CONCLUSIONS
Suggested concept of smart electrohydraulic press is presented in short
description with principal solutions for three constituent components:
sensing die, adaptive MEDB system and smart control system.
Practical realisation of this concept needs performance of large vol-
ume of design, manufacturing and investigation works.
Realisation of this concept will allow solving the problems of insta-
bility of impulse pressure fields, lack of specialised literature and
skilled EHF specialists as the conditions for wide industrial implemen-
tation of EHF technology that finally will bring big economical effect.
REFERENCES
1. Yu. I. Chebanov, Physical and Technical Aspects of Electric Explosive
Converting of Energy (Kiev: Naukova Dumka: 1990), p. 89 (in Russian).
2. M. K. Knyazyev, Proc. of the 4
th
International Conference ‘Supply on the Wings’
(Frankfurt-am-Main: 2009), p. 16.
3. M. E. Taranenko, Elektrogidravlicheskaya Shtampovka: Teoriya,
Oborudovanie, Tekhprotsessy [Electrohydraulic Forming: Theory, Equipment,
Manufacturing Processes] (Kharkiv: National Aerospace University Named
After M. Ye. Zhukovsky ‘Kharkiv Aviation Institute’: 2011) (in Russian).
1680 M. K. KNYAZYEV and Ch. BEERWALD
4. M. K. Knyazyev and Yu. V. Protsan, Proc. of the 17th International Congress
Propulsion Engineering (Kharkiv: National Aerospace University Named After
M. Ye. Zhukovsky ‘Kharkiv Aviation Institute’: 2012), p. 143 (in Russian).
5. M. K. Knyazyev and Yu. V. Protsan, Visnyk Natsional’nogo Tekhnichnogo
Universytetu ‘KhPI’. Seriya: Novi Rishennya v Suchasnykh Tekhnologiyakh,
No. 46: 63 (2012) (in Russian).
6. M. K. Knyazyev and Ya. S. Zhovnovatyuk, Proc. 20th
Anniversary International
Conference on Metallurgy and Materials METAL 2011 (May 18—20, 2011)
(Brno: 2011), p. 6.
7. M. K. Knyazyev and D. M. Tkachenko, Proc. International Scientific
Conference ‘Integrated Computer Technologies in Machine-Building
ICTM-2009’ (Kharkiv: National Aerospace University Named After
M. Ye. Zhukovsky ‘Kharkiv Aviation Institute’: 2009), vol. 1, p. 51
(in Russian).
8. K. J. Еström and B. Wittenmark, Computer-Controlled Systems: Theory and
Design (Mineola, NY: Dover Publication: 2013).
9. K. J. Еström and B. Wittenmark, Adaptive Control (Mineola, NY: Dover
Publication: 2008).
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/NLD (Gebruik deze instellingen om Adobe PDF-documenten te maken die zijn geoptimaliseerd voor prepress-afdrukken van hoge kwaliteit. De gemaakte PDF-documenten kunnen worden geopend met Acrobat en Adobe Reader 5.0 en hoger.)
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/UKR <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>
/ENU (Use these settings to create Adobe PDF documents best suited for high-quality prepress printing. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)
>>
/Namespace [
(Adobe)
(Common)
(1.0)
]
/OtherNamespaces [
<<
/AsReaderSpreads false
/CropImagesToFrames true
/ErrorControl /WarnAndContinue
/FlattenerIgnoreSpreadOverrides false
/IncludeGuidesGrids false
/IncludeNonPrinting false
/IncludeSlug false
/Namespace [
(Adobe)
(InDesign)
(4.0)
]
/OmitPlacedBitmaps false
/OmitPlacedEPS false
/OmitPlacedPDF false
/SimulateOverprint /Legacy
>>
<<
/AddBleedMarks false
/AddColorBars false
/AddCropMarks false
/AddPageInfo false
/AddRegMarks false
/ConvertColors /ConvertToCMYK
/DestinationProfileName ()
/DestinationProfileSelector /DocumentCMYK
/Downsample16BitImages true
/FlattenerPreset <<
/PresetSelector /MediumResolution
>>
/FormElements false
/GenerateStructure false
/IncludeBookmarks false
/IncludeHyperlinks false
/IncludeInteractive false
/IncludeLayers false
/IncludeProfiles false
/MultimediaHandling /UseObjectSettings
/Namespace [
(Adobe)
(CreativeSuite)
(2.0)
]
/PDFXOutputIntentProfileSelector /DocumentCMYK
/PreserveEditing true
/UntaggedCMYKHandling /LeaveUntagged
/UntaggedRGBHandling /UseDocumentProfile
/UseDocumentBleed false
>>
]
>> setdistillerparams
<<
/HWResolution [2400 2400]
/PageSize [612.000 792.000]
>> setpagedevice
|