MSE Seminar: Ryan Brune, Effect of Geometrical Parameters on Pressure Distributions of Impulse Manufacturing Technologies

Abstract

Impulse manufacturing technologies, which include vaporizing foil actuator (VFA) and electromagnetic (EM) methods, offer a wide array of capabilities for enabling new sheet metal part designs, which can be applied to automotive, appliance, and aerospace products. Geometrical parameter variation of the primary conductors and assembly configurations were investigated for both technologies, helping to understanding how these processes can best be optimized and integrated into manufacturing settings. A novel approach for quantifying and mapping pressure output was developed called the Profile Indentation Pressure Evaluation (PIPE) method. As the result of an impulse operation, a flat metal transducer sheet is accelerated against a textured surface with regularly spaced profile peaks, and the indented local area fraction is correlated with pressure quantities. This technique was applied to EM path actuators for shearing, flanging, and hemming operations to assess the accuracy of existing pressure models and support a new analytical model. A design process for path actuator systems was then developed based on this new model. Additionally, application of PIPE to VFA forming and embossing cases revealed the effect of initial foil geometry on pressure distribution, assisting experimental studies on improvement of final die conformity and feature detail transfer on aluminum and stainless steel products. Additionally, these materials were evaluated for suitability in high velocity forming applications via custom conical die testing and sample geometry variation to elicit strain states associated with traditional forming limit diagrams. Formed samples were evaluated with photon doppler velocimetry and digital image correlation to determine performance in comparison to quasi-static forming techniques.

Bio

Ryan Brune has been a research associate for the Impulse Manufacturing Laboratory at The Ohio State University since 2011. He received his BS in Mechanical Engineering from Ohio Northern University in 2011, and his MS in Materials Science and Engineering from The Ohio State University in 2013. Ryan’s past internships involved researching applications of electromagnetic forming technology, which led him to join Dr. Glenn Daehn’s research group to continue working with this interesting field. He continues to enjoy witnessing the application of this and other impulse technologies to manufacturing settings as more people discover all that they can be used for.