A HYBRID QUASI-STATIC / DYNAMIC PROCESS FOR FORMING LARGE SHEET METAL PARTS FROM ALUMINUM ALLOYS
 
 

THE OHIO STATE UNIVERSITY
 
 

Dept. of Industrial Systems and Welding Engineering
 
 
 

By

Vincent J. Vohnout

1998
 
 
 
 

Advisor: Dr. Rajiv Shivpuri

Committee:

Dr. Glenn Daehn, Dept. Material Science and Engineering

Dr. William Baeslack III, Dept. of Industrial Systems and Welding Engineering
 

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TABLE OF CONTENTS

[See Copyright Information]



 
 
 
 
 

Abstract

Dedication

Acknowledgments

Vita

Publications

1.  Introduction

1.1 Matched Tools

1.2 Fluid Pressure Forming

1.3 High Velocity Forming

1.3.1 Electromagnetic

1.3.2 Electro-hydraulic

1.4 Overview of Thesis

2.  Specific problem description and proposed solution
2.1 Combined Quasi-Static and Dynamic Forming: Hybrid Methods

2.2 Advantages of Different Hybrid Methods

2.3 Issues Involved in Developing MT-EM Forming

3.  Effects of electromagnetic pulse forming on work hardned material
3.1 Experimental Determination of the Effect of Static Prestrain and Eddy Currents on Limit Strains

3.2 Thermal Effects in Coupon Electromagnetic Bulging

3.3 Factorial Experiment on MT-EM Process Parameters

3.4 Summary of Coupon Experiment Results

4.  Process simulation and software tools
4.1 Introduction

4.2 Quasi-Static Process Model Requirements

4.3 Full Dynamic Model for MT-EM Forming; the GEM Code

5.  Application design and trials of the MT-EM process
5.1 Introduction

5.2 General Design Considerations

5.3 Full Scale MT-EM Trials

5.3.1 Automotive Hood Feature Line Extension Trial

5.3.2 Automotive Door Inner Panel Trial

5.4 Future Work

Bibliography

Appendix A

Appendix B