Electrohydraulic Forming of Near-Net Shape Automotive Panels

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The objective of this project was to develop the electrohydraulic forming (EHF) process as a near-net shape automotive panel manufacturing technology that simultaneously reduces the energy embedded in vehicles and the energy consumed while producing automotive structures. Pulsed pressure is created via a shockwave generated by the discharge of high voltage capacitors through a pair of electrodes in a liquid-filled chamber. The shockwave in the liquid initiated by the expansion of the plasma channel formed between two electrodes propagates towards the blank and causes the blank to be deformed into a one-sided die cavity. The numerical model of the EHF ... continued below

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5.443 MB

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Golovaschenko, Sergey F. September 26, 2013.

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Description

The objective of this project was to develop the electrohydraulic forming (EHF) process as a near-net shape automotive panel manufacturing technology that simultaneously reduces the energy embedded in vehicles and the energy consumed while producing automotive structures. Pulsed pressure is created via a shockwave generated by the discharge of high voltage capacitors through a pair of electrodes in a liquid-filled chamber. The shockwave in the liquid initiated by the expansion of the plasma channel formed between two electrodes propagates towards the blank and causes the blank to be deformed into a one-sided die cavity. The numerical model of the EHF process was validated experimentally and was successfully applied to the design of the electrode system and to a multi-electrode EHF chamber for full scale validation of the process. The numerical model was able to predict stresses in the dies during pulsed forming and was validated by the experimental study of the die insert failure mode for corner filling operations. The electrohydraulic forming process and its major subsystems, including durable electrodes, an EHF chamber, a water/air management system, a pulse generator and integrated process controls, were validated to be capable to operate in a fully automated, computer controlled mode for forming of a portion of a full-scale sheet metal component in laboratory conditions. Additionally, the novel processes of electrohydraulic trimming and electrohydraulic calibration were demonstrated at a reduced-scale component level. Furthermore, a hybrid process combining conventional stamping with EHF was demonstrated as a laboratory process for a full-scale automotive panel formed out of AHSS material. The economic feasibility of the developed EHF processes was defined by developing a cost model of the EHF process in comparison to the conventional stamping process.

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5.443 MB

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  • Report No.: DOE-FORD-GO18128
  • Grant Number: FG36-08GO18128
  • DOI: 10.2172/1094831 | External Link
  • Office of Scientific & Technical Information Report Number: 1094831
  • Archival Resource Key: ark:/67531/metadc827539

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Office of Scientific & Technical Information Technical Reports

Reports, articles and other documents harvested from the Office of Scientific and Technical Information.

Office of Scientific and Technical Information (OSTI) is the Department of Energy (DOE) office that collects, preserves, and disseminates DOE-sponsored research and development (R&D) results that are the outcomes of R&D projects or other funded activities at DOE labs and facilities nationwide and grantees at universities and other institutions.

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Creation Date

  • September 26, 2013

Added to The UNT Digital Library

  • May 19, 2016, 9:45 a.m.

Description Last Updated

  • July 22, 2016, 4:29 p.m.

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Golovaschenko, Sergey F. Electrohydraulic Forming of Near-Net Shape Automotive Panels, report, September 26, 2013; United States. (digital.library.unt.edu/ark:/67531/metadc827539/: accessed September 23, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.