Detonation forming of aluminium cylindrical cups experimental and theoretical modelling

In this study, cylindrical cups formation of aluminium alloy sheets using a gas detonation forming system (DIN 99.5 (Etial 5)) was investigated. This system was achieved by accepting the volume ratio of acetylene (C2H2)–oxygen (O2) being equal, and double staged detonation forming apparatus was designed and manufactured. For this purpose, the complete filling up of the DSDT with reactant was controlled by a manometer and a flow-meter being operated by computer software. Shock speed and pressure values of the gas detonation being applied to the forming cups were recorded by a computer-controlled system. The amount of formability of aluminium cups in the cylindrical moulds was measured and analyzed.The theoretical model of the formed cups’ shape was realized and analyzed with the help of ‘the explicit dynamic analysis code’ module incorporated ANSYS/LS-DYNA computer software. The comparison of the experimental and theoretical results obtained from unit strain, thickness variation and volume of cups formability was carried out. Theoretical and experimental results showed approximately 80–90% similarities in formability of desired shape and inconsistencies between these two models were investigated to find out optimum formability of cups and ratio of reactant, based upon the above mentioned theoretical and experimental results.