Electrically vaporizing foil actuators are employed as an innovative high speed sheet metal forming technology, which has the potential to lower tool costs. To reduce experimental try-outs, a predictive physics-based process design procedure is developed for the first time. It consists of a mathematical optimization utilizing numerical forming simulations followed by analytical computations for the forming-impulse generation through the rapid Joule heating of the foils. The proposed method is demonstrated for an exemplary steel sheet part. The resulting process design provides a part-specific impulse distribution, corresponding parallel actuator geometries, and the pulse generator’s charging energy, so that all process parameters are available before the first experiment. The experimental validation is then performed for the example part. Formed parts indicate that the introduced method yields a good starting point for actual testing, as it only requires adjustments in the form of a minor charging energy augmentation. This was expectable due to the conservative nature of the underlying modeling. The part geometry obtained with the most suitable charging energy is finally compared to the target geometry.

电汽化箔致动器被用作一种创新的高速钣金成型技术，具有降低工具成本的潜力。为了减少试验次数，首次开发了基于预测物理的工艺设计程序。它包括利用数值成形模拟的数学优化，然后是通过箔的快速焦耳加热生成成形脉冲的分析计算。针对示例性钢板部件展示了所提出的方法。由此产生的工艺设计提供了特定于零件的脉冲分布、相应的并行执行器几何形状和脉冲发生器的充电能量，以便在第一次实验之前可以获得所有工艺参数。然后对示例部分进行实验验证。成型零件表明，引入的方法为实际测试提供了一个良好的起点，因为它只需要以较小的充电能量增强的形式进行调整。由于基础建模的保守性质，这是可以预料的。以最合适的充电能量获得的零件几何形状最终与目标几何形状进行比较。