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Electrohydraulic forming (EHF) is a high velocity forming process in which the electric energy stored in the capacitors are suddenly discharged between two electrodes submerged in a water-filled chamber. During the discharge, the water between the electrodes vaporizes and creates a shock wave that is transferred to the blank using the water and forms it. One of the key parameters in electrohydraulic forming is the determination of the suitable position of the electrodes. In this research the effect of electrodes position in electrohydraulic free-forming is investigated using the finite element simulation. First the experiments available in the literature is simulated using the software ABAQUS/ Explicit and compared with the experimental results which shows good agreement with. Then by changing the position of the electrodes, the effect of their position on the formability and thickness distribution of the blank is investigated. The results indicates that the forming a component is only possible in limited positions of the electrodes and there is a position for the electrodes that not only improves the sheet thickness but also decreases the possibility of the failure.

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Nowadays high velocity forming methods have become popular among industrial companies due to their capability at improving formability in various materials in comparison to conventional methods. Electrohydraulic forming (EHF) is a high velocity sheet metal forming process in which two electrodes are positioned in a water filled chamber and a high-voltage discharge between the electrodes generates a high-pressure to form the sheet metal. In this work, extensive experimental tests have been designed based on design of experiments (DOE) technique to investigate the effective parameters in EHF (with bridge wire between electrodes). Discharge energy, material, length and diameter of bridge wire have been considered as effective input parameters. Response surface methodology (RSM) has been used to model and optimize the EHF performance with respect to drawing depth for Brass 260. Base on the results, it can be stated that maximum drawing depth is obtained when discharge energy is maximum. It was found that the aluminum wire was more efficient than copper and tungsten. There also exists an optimum amount of length and diameter of bridge wire determined according to the process conditions.