UNIVERSITI PUTRA MALAYSIA NUMERICAL ANALYSIS OF SHOCK WAVE PROPAGATION AND AL5083 SHEET BULGING IN EXPLOSIVE HYDRO FORMING PROCESS SAEED JABALAMELIAN

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1 UNIVERSITI PUTRA MALAYSIA NUMERICAL ANALYSIS OF SHOCK WAVE PROPAGATION AND AL5083 SHEET BULGING IN EXPLOSIVE HYDRO FORMING PROCESS SAEED JABALAMELIAN FK

2 NUMERICAL ANALYSIS OF SHOCK WAVE PROPAGATION AND AL5083 SHEET BULGING IN EXPLOSIVE HYDRO FORMING PROCESS By SAEED JABALAMELIAN Thesis Submitted to the School of Graduate Studies,, in Fulfillment of the Requirement for the Degree of Master Science January 2012

3 DEDICATION To my beloved parents, that I owe them my entire life To my supervisor Dr. Aidy Ali who taught me how to be a good researcher To my compassionate wife, Saeedeh, that without her support I will not be able to complete this dissertation. II

4 Abstract of thesis presented to the Senate of in fulfillment of the requirement for the degree of Master of Science NUMERICAL ANALYSIS OF SHOCK WAVE PROPAGATION AND AL5083 SHEET BULGING IN EXPLOSIVE HYDRO FORMING PROCESS Chairman Faculty By SAEED JABALAMELIAN January 2012 : Associate Professor Aidy Ali, PhD : Engineering The present work simulated the explosive forming of a torisperical dished head from the Al-5083 aluminum alloy against a male die. The simulation was used to investigate the strain distribution across the final product as well as to capture the complex nature behind this High Energy Rate Forming (HERF) technique. The study was carried out in the framework of LS-DYNA code, based on the Arbitrary Lagrangian Eulerian (ALE) Multi-Material formulation, which provided a finite element mesh that moved independently from the material flow and allowed each element to contain a mixture of two or more different materials. The underwater explosion phenomenon including the shock wave propagation and the state of detonation products was perfectly simulated using the Jones-Wilkins-Lee (JWL) and Gruneisen equations of state for explosive and water, respectively. The results were validated based on the Cole s experimental and analytical works on underwater explosion of relatively small charge, which showed the average error of 6.4%. The simulation outcomes showed that the primary shock could be modified by accelerating the specimen up to 100 m/s and reflecting back toward the water, which could lead to cavitations. The formation of the cavitations and their effects on the III

5 deformation of the specimen were investigated numerically; same as the other aspects of the desired process. Since many of these phenomena were too difficult to be investigated experimentally, a comprehensive understanding of the Explosive Hydro Forming (EHF) process was achieved through a numerical simulation in this study. The behavior of the specimen under explosive loading was predicted according to the Johnson-Cook (JC), Modified Zerilling-Armstrong (MZA) and Plastic-Kinematic (PK) constitutive equations, which were used to investigate the strain distribution across the final product. Moreover, three techniques were examined numerically involving increasing the ratio between the thickness and diameter of sheet plate, using the sheet holder and grooving the edge of the workpiece to reduce the wrinkling at the edge of the workpiece. IV

6 Abstrak tesis yang dikemukakan kepada Senat sebagai memenuhi keperluan untuk ijazah Master Sains ANALISA BERANGKA TERHADAP PENYEBARAN GELOMBANG KEJUTAN DAN PROSES BENJOLAN KEPINGAN AL5083 DALAM PROSES PEMBENTUKAN LETUPAN HIDRO Oleh SAEED JABALAMELIAN Januari 2012 Pengerusi : Profesor Madya Aidy Ali, PhD Fakulti : Kejuruteraan Kajian ini melibatkan simulasi pembentukan menggunakan peledak ke atas penutup torisferikal yang diperbuat daripada aloi aluminium AL-5083 menggunakan acuan. Simulasi ini digunakan untuk mengkaji pengagihan tekanan produk akhir serta untuk memahami teknik Pembentukan Kadar Tenaga Tinggi (HERF) yang kompleks. Kajian ini dijalankan dengan menggunakan rangka kerja berkod LS-DYNA, berdasarkan Formulasi bahan rencam Arbitrary Lagrangian Eulerian (ALE) yang menyediakan asas unsur terhad yang bergerak secara bebas daripada arus bahan dan membenarkan setiap elemen untuk mempunyai campuran dua atau lebih bahan yang berlainan. Fenomena ledakan dalam air seperti pengagihan gelombang kejut dan ledakan produk telah disimulasi secara tepat menggunakan persamaan-persamaan Jones-Wilkins-Lee (JWL) dan Gruneisen, masing-masing untuk ledakan dalam air. Hasil kajian tersebut telah disahkan oleh ujikaji dan hasil analisa Cole ke atas ledakan bawah air berskala kecil yang menunjukkan ralat maksimum 6.4 %. Hasilhasil simulasi menunjukkan gelombang kejutan pertama boleh diubahsuai dengan meningkatkan kelajuan spesimen sebanyak 100 m/s dan ditampan oleh air, di mana V

7 peronggaan akan berlaku. Pembentukan peronggaan dan kesan-kesannya ke atas herotan spesimen dikaji secara berangka, sama seperti aspek lain untuk proses tersebut. Memandangkan banyak fenomena agak sukar untuk dikaji melalui eksperimen, satu pemahaman menyeluruh terhadap proses Pembentukan Ledakan Hidro (EHF) telah tercapai melalui simulasi berangka melalui kajian ini. Perilaku spesimen di bawah muatan bahan ledakan telah diramalkan mengikut persamaan Johnson-Cook (JC), Zerilling-Armstrong (MZA) diubahsuai dan Plastic- Kinematic (PK), yang telah digunakan untuk mengkaji taburan terikan seluruh produk akhir. Selain itu, tiga teknik diperiksa secara berangka yang melibatkan peningkatan nisbah antara ketebalan dan diameter plat kunci, menggunakan pemegang dan alur pada hujung bahan kerja untuk mengurangkan kedutan. VI

8 ACKNOWLEDGEMENTS I hereby convey my heartfelt appreciation to my honored supervisor Assoc. Prof. Dr. Aidy Ali and co-supervisor Dr. Azmah Hanim Mohamed Ariff. That without their invaluable supports and worthwhile advices I will not be able to complete this work. Also I would like to express my gratefulness to Tn. Hj. Mhd. Yunin Hassan, my former supervisor, and all other faculty members who helped me to complete this dissertation. Furthermore, I would like to extend my appreciation to Dr. S. Borji as a pioneer in explosive metal working field, who affiliated me with explosive forming and encouraged me to work on this topic. Finally, I have to express my sincere gratitude to my beloved father, Hossein Jabalamelian, who supports me with his overwhelming efforts. VII

9 I certify that a Thesis Examination Committee has met on 10 January 2012 to conduct the final examination of Saeed Jabalamelian on his thesis entitled Numerical Analysis of Shock Wave Propagation and AL5083 Sheet Bulging in Explosive Hydro Forming Process in accordance with the Universities and University College Act 1971 and the Constitution of the [P.U.(A) 106] 15 March The Committee recommends that the student be awarded the Master of Science. Members of the Thesis Examination Committee were as Follows: Shamsuddin Sulaiman, PhD Professor Faculty of Engineering (Chairman) B. T. Hang Tuah bin Baharudin, PhD Senior Lecturer Faculty of Engineering (Internal Examiner) Barkawi bin Sahari, PhD Professor Faculty of Engineering (Internal Examiner) Shahrum Abdullah, PhD Professor Faculty of Engineering and Built Environment Universiti Kebangsaan Malaysia (External Examiner) SEOW HENG FONG, PhD Professor and Deputy Dean School of Graduate Studies Date: 23 April 2012 VIII

10 This thesis was submitted to the Senate of and has been accepted as fulfilment of the requirement for the degree of Master of Science. The members of the Supervisory Committee were as follows: Aidy bin Ali, PhD Professor Madya Faculty of Engineering (Chairman) Azmah Hanim bt. Mohamed Ariff, PhD Senior lecturer Faculty of Engineering (Member) BUJANG BIN KIM HUAT, PhD Professor and Dean School of Graduate Studies Date: IX

11 DECLARATION I declare that the thesis is my original work except for quotations and citation which have been duly acknowledged. I also declare that it has not been previously, and is not concurrently, submitted for any other degree at or other institutions. SAEED JABALAMELIAN Date: 10 January 2012 X

12 TABLE OF CONTENTS Page DEDICATION ABSTRACT ABSTRAK ACKNOWLEDGEMENTS APPROVAL DECLARATION LIST OF FIGURES LIST OF TABLES LIST OF ABBREVIATIONS LIST OF SYMBOLS CHAPTER 1 2 INTRODUCTION 1.1 Introduction 1.2 Problem Statement 1.3 Research Objective 1.4 Scope of Study 1.5 Layout of Thesis LITERATURE REVIEW 2.1 Introduction to High Rate Energy Forming 2.2 Explosive Metal Working Operations Explosive Forming Explosive Welding - Explosive Cladding - Explosive Bonding Explosive Hardening Reliving Residual Stresses 2.3 Advantageous, Limitations and Qualifications of Explosive Forming 2.4 Spheroid - Conical Section Free Forming Method Explosive Forming with Female Die Explosive Forming with Male Die 2.5 Metal forming by Shock Wave 2.6 Strain rate, Temperature Sensitive Constitutive Equation The Johnson-Cook (JC) model The Zerilli-Armstrong model The Steinberg-Guinan model The Steinberg-Lund model The Mechanical Threshold Stress (MTS) Model The Preston-Tonks-Wallace (PTW) model The Plastic-Kinematic model ii iii v vii viii x xiii xvi xvii xix XI

13 2.7 Discussion METHODOLOGY 3.1 Configuration of the Model Material properties 3.2 Developing the Finite Element Model Modeling the Configuration Define the problem nature and mesh generation Introducing the Materials Properties Modeling the behavior of water and air Modeling the explosive charge Set the Boundary and Initial Condition Check the Model Final Model Modifications and Assumptions 3.3 Discussion RESULTS AND DISCUSSION 4.1 Investigation the Shock Waves 4.2 Investigation the Expansion-Contraction Cycle 4.3 Investigation the Cavitations 4.4 Investigation the Pressure Profile 4.5 Deformation Mechanism First Group (D = 120 mm, t = 3.3 mm) Second Group (D = 140 mm, t = 3.2 mm) Third Group (D = 140 mm, t = 2.2 mm) Fourth Group (D = 120 mm, t = 3.3 mm with circumferential grooves) 4.6 Summary CONCLUSIONS AND RECOMENDATIONS 5.1 Conclusions 5.2 Recommendations for Future Research REFERENCES APPENDIXS BIODATA OF THE STUDENT XII