Electric-Pulse Energetic Forming of Metal Plates at Reduced Discharge Load
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for forming complex metal parts, such as aluminum alloy 7A09, magnesium alloy AZ31, and titanium alloy TC4, face challenges with poor formability at room temperature, leading to high costs and long processing times, and existing high-rate forming techniques like explosive, electrohydraulic, and electromagnetic forming have limitations in energy distribution, safety, and precision.
Innovation Solution
A method and device using a high-energy electric pulse to drive energetic materials (EMs) in combination with electrohydraulic forming, which includes a device with an upper and lower die, a high-energy electric pulse forming system, and an energetic rod, allowing for precise formation of difficult-to-form metal plates at room temperature by controlling energy release through a metal wire and EMs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional electrohydraulic forming is used to increase discharge energy by increasing discharge voltage, then the forming limit and plastic deformation ability are improved, but the discharge loop current sharply increases causing equipment to work in high load state, reducing safety and service life
Solution Approach 1:
The patent introduces energetic materials as an intermediary substance between the electric pulse and the metal plate. The electric pulse triggers the energetic materials to undergo rapid chemical reaction, which then generates the forming pressure. This mediator approach allows energy to be delivered through chemical reaction rather than direct electrical discharge, avoiding the high current damage to equipment while achieving the required forming effect.
Solution Approach 2:
The patent replaces the traditional electrohydraulic system (which uses electrical discharge to generate hydraulic pressure) with a chemically-driven system. Instead of using electrical energy to directly create mechanical pressure through liquid, the system uses chemical energy from energetic materials to generate the forming force, substituting the mechanical-electrical energy conversion path with a chemical-mechanical path that is more equipment-friendly.
2Speed
If electromagnetic forming is used for high-rate forming, then the forming speed is improved, but it can only be applied to high-conductivity plates and encounters problems of uneven distribution of electromagnetic force and poor modeling of small fillets
Solution Approach 1:
The patent changes the fundamental parameter of energy delivery from electromagnetic induction (which depends on material conductivity) to chemical reaction driven by electric pulse. This parameter change allows the system to work on materials regardless of their electrical conductivity, as the forming force comes from the chemical reaction of energetic materials rather than electromagnetic induction in the workpiece.
Solution Approach 2:
The patent enables localized energy release by positioning the energetic materials precisely where forming is needed. The electric pulse triggers the energetic materials at specific locations, creating localized high-pressure zones that can be precisely controlled to achieve complex geometries and small fillets with uniform quality, unlike electromagnetic forming where the electromagnetic force distribution is inherently uneven.
3Strength
If heating is used to improve formability of metal plates, then the plastic deformation ability is improved, but the working process takes a long time and high costs
Solution Approach 1:
The patent uses periodic pulsed electric discharge to trigger the energetic materials. The high-power electric pulse is applied in very short duration (microseconds to milliseconds), creating a rapid, periodic energy input that generates instantaneous high pressure for forming. This pulsed action achieves the forming effect in one rapid cycle rather than through prolonged heating, dramatically reducing processing time while maintaining high formability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables precise and efficient high-rate forming of complex metal parts with improved energy distribution and safety, reducing equipment load and extending its service life, while allowing for automated manufacturing without the need for preheating or lubrication.
Implementation Method 1
a high-energy electric pulse to drive energetic materials (EMs)... the EMs are formed by mixing two or more of aluminum powder, ammonium nitrate, ammonium perchlorate, copper oxide
Implementation Method 2
a discharge capacitor bank, a charging switch, a current limiting resistor, a high-voltage rectifier... open a discharge trigger signal source to control an auxiliary discharge gap to discharge the energetic rod
Data Source
AI summary
The present disclosure discloses a device and a method for forming a metal plate by using a high-energy electric pulse to drive an energetic material. The device includes high-energy pulse discharge equipment, an intelligent robot arm control system, a vacuum pumping device, a hydraulic press, a forming die, positive and negative electrodes, an energetic rod, and liquid supply equipment. According to the present disclosure, energy of a metal wire is added to energy of an energetic material after energy release to implement high-rate forming of the plate. A discharge voltage of the high-energy pulse discharge equipment is reduced and a service life thereof is prolonged. The discharge equipment is triggered by the manufactured small-size electric pulse metal wire, thereby reducing a volume and costs of the equipment and miniaturizing the equipment to implement precise operating, forming, and intelligent integration with the robot arm control system.