Flexible tool design with shear thickening fluids in impulse forming processes

The focus of the project is on increasing the flexibility of the vaporization vaporizing foil actuator forming process for small batch production. In this process, massive, inflexible steel dies are replaced by thin, flexible, additively manufactured shells, which are suitable for unique part geometries. These shells are supported by shear-thickening fluids (STF). The fluid is initially liquid and solidifies instantaneously under the high strain rates caused by the impact of the workpiece. The fluid fill level has no influence on the forming result, where even a 5 mm layer is sufficient to stabilize the die. However, the concentration of the STF significantly affects the forming result and must be selected to ensure instant solidification. Numerically, the vaporization process can be modelled through a pressure amplitude with an enlarged pressure surface. The STF is represented by an equation of state and corresponding viscosity, enabling the design of the die to withstand the impact of the workpiece.

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