Hyperplastic forming: Process potential and factors affecting formability

Aluminum has an outstanding potential for reducing the mass of automobiles. One of the key problems is that it is very difficult to form without tearing. This paper has two distinct goals. First, the authors argue in an extended introduction that high velocity forming, as can be implemented through electromagnetic forming, is a technology that should be developed. As a process used in conjunction with traditional stamping, it may offer dramatically improved formability, reduced wrinkling and active control of springback among other advantages. In the body of the paper they describe the important factors that lead to improved formability at high velocity. In particular, high sample velocity can inhibit neck growth. There is a sample size dependence where larger samples have better ductility than those of smaller dimensions. These aspects are at least partially described by the recent model of Freund and Shenoy. In addition to this, boundary conditions imposed by sample launch and die impact can have important effects on formability.