Part-optimized forming by spatially distributed vaporizing foil actuators

Abstract Electrically vaporizing foil actuators are employed as an innovative high speed sheet metal forming technology, which has the potential to lower tool costs. To reduce experimental try-outs, a predictive physics-based process design procedure is developed for first time. It consists of mathematical optimization utilizing numerical simulations followed by analytical computations forming-impulse generation through rapid Joule heating foils. The proposed method demonstrated exemplary steel part. resulting provides part-specific impulse distribution, corresponding parallel actuator geometries, and pulse generator’s charging energy, so that all parameters available before experiment. validation then performed example Formed parts indicate introduced yields good starting point actual testing, it only requires adjustments in form minor energy augmentation. This was expectable due conservative nature underlying modeling. part geometry obtained with most suitable finally compared target geometry.