Numerical modelling of electrohydraulic forming

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The increasing use of high strength steels and lower density materials in passenger vehicles has created significant challenges for manufacturers who form them into body and chassis components. The limited formability of these lightweight materials has led to increased manufacturing costs and decreased design flexibility, when conventional forming processes such as stamping and hydroforming are utilized. Consequently, more advanced forming processes are being explored. One of the most promising of these advanced forming processes is electrohydraulic forming (EHF), which consists of discharging a high voltage current between two electrodes submerged in a fluid, and using the pressure wave in the fluid to form a sheet metal blank against a die at very high strain rates. EHF is attractive because it is extremely fast, can be used with any type of sheet material (steel or aluminum), and significantly reduces tooling costs compared to conventional processes that use mating dies. Furthermore, preliminary research has shown that, in EHF, the formability of steel and aluminum can increase by a factor of two or more. The main objectives of this research program are (a) to develop models that are able to accurately predict the behaviour of sheets that are formed with an electrohydraulic pulse, and (b) to implement these models into numerical programs that can be used to simulate EHF processes. This research will provide training for four highly qualified personnel in a state-of-the-art forming technology. This research program will generate new knowledge and advanced modelling capabilities. Ultimately, the adoption of EHF by the automotive industry in Canada will help to promote the use of higher strength and lower density materials, which will also help decrease vehicle weight and carbon emissions.