Papers abstract:

Electro-hydraulic forming is one of the unique processes of high-velocity forming. In this process, the electrical energy is converted into mechanical energy in the form of shock waves within a liquid medium. This energy is utilized to perform redundant work, to overcome friction, and to form the work-piece to its final shape. This process is similar to explosive forming, with the main difference being the energy source. The paper analyzes electrical discharge parameters and simulates the EHF process using the finite element method in Abaqus. Materials studied include mild steel (IF210), high strength steel (DPX800), and stainless steel (1.4509), using dynamic explicit analysis with volume acceleration loading. Simulation results correlate well with experimental outcomes.

Product Overview:
This tutorial guides you through the simulation of the EHF process using acoustic volume acceleration instead of modeling the complex electrical discharge directly. This method simplifies implementation while maintaining physical accuracy in predicting strain and dome height. Key simulation steps include:

• defining the blank, water, and rigid die geometries
• Assigning Johnson-Cook plasticity to sheet metals
• Applying tie constraints between fluid and structural domains
• Using acoustic inward volume acceleration to simulate shockwave pressure
• Meshing the sheet with refined seeding near edges
• Matching dome height with experimental data for calibration

In this tutorial, dome-shaped sheet metal forming processes are simulated, according to data from the work of Zohoor and Hosseini.