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Preliminary examination of high-velocity metal-shaping with electrical wire explosion

Preliminary examination of high-velocity metal-shaping with electrical wire explosion. EAPPC 2006 – Speaker: Mirko Woetzel. Overview. Some remarks about explosive shaping Replacement of explosives by “Electro-explosives” Direct experimental comparison of “electro-explosives” and explosives

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Preliminary examination of high-velocity metal-shaping with electrical wire explosion

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  1. Preliminary examination ofhigh-velocity metal-shaping withelectrical wire explosion EAPPC 2006 – Speaker: Mirko Woetzel

  2. Overview • Some remarks about explosive shaping • Replacement of explosives by “Electro-explosives” • Direct experimental comparison of “electro-explosives” and explosives • Discussion of the results

  3. Shaping with Explosives Workpiece hits the matrix with>100 m/s

  4. Shaping with Explosives DISADVANTAGES • Use of explosives strongly regulated by laws • Extensive safety measures • Special skilled staff • In-house production very critical •  too expensive for series production! ADVANTAGES • Very easy to use under special conditions • Used for prototype production • Low tool cost

  5. Shaping with Explosives • How the advantages of explosive shaping can be used without its disadvantages? • Approach: • Replacement of explosives by “inert” materials • Suggestion: high power arc, wire explosion • Very well known processes • But, with respect to sheet metal shaping: • No direct comparison of “electro-explosives” available • No direct comparison with explosives available

  6. Electro-explosive Shaping Parameters: • Different “electro-explosive” media aluminum wire, copper wire and electrical arc • Different environmentswater, oil or air • Constant electrical energy input1000 Joule

  7. Volume: 65 ml water, oil or air  wires: 0.7 mm Test box (1) Aluminium – Master-Frame (2) Teflon – Isolator of electrodes (3) Smooth Copper – Seal (4) Aluminium – Shaping Matrix 20 mm (1) (2) (3) (4)

  8. Energy-Supply C = 20 µF VC0 = 10 kV WC0 = 1 kJ

  9. Energy supply Mounting plate Rogowski coil Conductor Capacitor

  10. Open test box Metal-sheet inside Closed test box filled with water, oil or air Capacitor discharge: Test realization “electro-explosive” Dismantled test box  Evaluation î = 30 kA f=50 kHz

  11. Test realization “explosive” • primary explosive 100 mg (lead azide detonator) • explosive 185 mg 285 mg explosive with <1,3 kJ energy

  12. Evaluation “electro-explosion” 3 Environment

  13. Environment: • WaterMaterial: • Aluminum Environment: • WaterMaterial: • Explosive Comparison “electro-explosive” vs. explosive

  14. Advantages of • no reaction with outside effects • no special skilled staff • easy storage and transportation • not usable for the crime scene • no toxic gases Electro-Explosive Shaping

  15. Conclusion • An electro-explosive metal-shaping process was investigated: Reactive Al-wire/water explosion yields the best shaping result • At comparable energies comparable results obtained for both electro-explosive and explosive shaping procedures • Safety aspects • Electro-explosive system=water+aluminum+voltage=“very safe” • Explosive system=explosives+water+laws+laws+…=“not too safe”

  16. Future work • Minimization of electrical energy requirements (investment and operation cost!) • Proof of principle for large sheet metals • Automation • Introduction to industry

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