AUT Journal of Electrical Engineering

AUT Journal of Electrical Engineering

A Multiphysics Pressure-Driven Framework for Electrohydraulic Sheet Metal Forming: Numerical Modeling and Formability Evaluation

Document Type : Research Article

Authors
1 Laboratory of Electrical Engineering and Industrial Electronics, Faculty of Science and Technology, University of Jijel, Jijel, 18000, Algeria
2 Department of Electrical Engineering, University of Jijel, Jijel, 18000, Algeria
10.22060/eej.2026.25813.6014
Abstract
Electrohydraulic Forming (EHF) is a high-speed forming process that converts electrical energy into mechanical work through an underwater spark discharge, generating a shockwave that deforms a metal sheet into a die. In this paper, we present a numerical model developed in COMSOL Multiphysics to simulate both free forming and die forming of thin sheets. The model treats the electrical discharge as a static pressure applied at the midpoint of the electrodes, replacing the shockwave with a static pressure. Simulations were carried out for Aluminum, Copper, and Steel sheets under varying pressures (10^4–10^5 Pa). Free-forming results show that displacement increases nearly linearly with pressure, with maximum central deflections of approximately 42mm for aluminum, 30mm for copper, and 20mm for steel at the maximum applied pressure of 10^5 Pa, indicating that aluminum exhibits the highest elastic compliance, followed by copper and steel. It should be noted that these results are obtained within a linear-elastic framework; a complete formability assessment would require the inclusion of plasticity, strain hardening, and strain-rate effects. Die-forming simulations with conical and truncated-conical dies reveal incomplete die filling, consistent with experimental observations. A time-dependent analysis using a sinusoidal pressure pulse demonstrates the transient deformation behavior.
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Articles in Press, Accepted Manuscript
Available Online from 23 September 2026