Eugene Ryzer | Kevin Fernandes AEM Power Systems | Macrodyne Technologies Inc.

1. MACRODYNE HYDRAULIC PRESSES
AEM & Macrodyne Gas Oscillation Super Plastic Forming (GO-SPF)

2. Company Profile: Overview & Product Areas
Presses
&
Automation
Hydraulic Presses from 50 – 30,000 Tons
Turnkey Hydraulic Press Lines
Custom Press Line Automation
Automated Die Storage & Retrieval Systems
Die Carts, Die Elevators Die Transfer Tables, Rolling
Bolsters
Die Storage Racks, Die Carrier Plates, Die Clamping
Packages
Die Handling
Service &
Retrofits
Retrofits, rebuilds & upgrades for all brands of hydraulic presses
Preventative maintenance, trouble-shooting & repair services
Spare & replacement parts
 Over 30 years in business, $100M+ Revenue, 150+ Employees Globally
 Presses supplied to North & South America, Europe and Asia
 Manufacturing & service locations in Canada, USA and Germany
 Service Partners: UK, Mexico, Additional Capacity in USA
 Our Global Presence:
 North America – Macrodyne Technologies Inc (Canada and USA)
 Europe- Asia - Dunkes (A Macrodyne company in Germany)

3. Partnership
 AEM has developed novel patented technology to drastically increase maximum strain and
decrease cycle times during forming by an order of magnitude
 TRL 8 demonstration is happening early spring with commercialization to follow immediately after
 Currently working with early adaptors in industries including: Marine, Aerospace, Automotive, and
Consumer Goods
 Key highlights:
 Forming up to 20x faster than traditional SPF
 More complex and detailed features than traditional SPF
 Able to make traditional stamped parts in one process instead of progressive die or multiple
parts with welding

4. Gas Oscillation Forming Technology
for
Oscillation Enhanced SPF

5. Why Improve SPF ?
Slow forming time
3 - 25 minutes - Automotive panels
1 - 8 hours - Aerospace panels
How to Improve SPF ?
Improve Forming Tool “Gas” – compressible fluid
Gas can be Oscillated to act as a Hammer
In Process Dynamic Stress Relieve with minor gas oscillations

6. In Process Dynamic Stress Relieve
Each generated minor gas oscillation deforms the material
and subsequently allows for partial stress relieve
Pressure
Time Improved grain boundary
sliding mechanism
Pressure
Time
SPF OESPF

7. Intellectual Property
US & Canadian Patent
EU Patent Pending Approval
New Patent Application July 2022

8. Gas Oscillation Forming Technology
R&D 2009 – 2021
Metal Forming
Fluid Dynamics
AEM & Macrodyne –
NGen.ca
Collaborative Technology
Demonstration Project
Gas Oscillation Forming
System
Commercialization 2023

9. Gas Oscillation Forming System
Metal Forming Fluid Dynamics
 Material characterization at various
amplitudes and frequencies
 Development of constitutive model
 FEA simulation with oscillation
 Design of Gas Oscillation Forming System
with Supersonic Fluidic Oscillator to
generate minor gas oscillations of required
frequency and amplitude to match FEA
part simulations
• Tool Design dependent
• Part Geometry dependent
• Forming Material dependent

10. Demonstration Project AA5083 1.4mm thick
Wide......
Long…...
Height….
825 mm (32.50”)
870 mm (34.25”)
616 mm (24.25”)
2 Cavity Tool

11. 300
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 50 100 150 200 250 300
Pressure
(Psi)
Strain
rate
(
1/second)
Time (seconds)
FEA Simulation SPF AA5083
60 90 150
120 180 240
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 50 100 150 200 250 300
Pressure
(Psi)
Strain
rate
(
1/second)
Time (seconds)
150
60 90 150
120 180 240
300

12. 300
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 50 100 150 200 250 300
Pressure
(Psi)
Strain
rate
(
1/second)
Time (seconds)
FEA Simulation SPF AA5083
Limit
60 90 150
120 180 240
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 50 100 150 200 250 300
Pressure
(Psi)
Strain
rate
(
1/second)
Time (seconds)
150
Peak Strain Rate
During forming
Entire Part
120
90
60
180
240 300
60 90 150
120 180 240
300

13. FEA Simulation SPF vs OESPF AA5083
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 5 10 15 20 25 30 35 40 45 50 55 60
Pressure
(Psi)
Strain
rate
(1/second)
Time (seconds)
60
Limit
SPF
60
60
16 19 25 32 44
62
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 5 10 15 20 25 30 35 40 45 50 55 60
Pressure
(Psi)
Strain
rate
(1/second)
Time (seconds)
60
Limit
SPF
32
25
16 19
16 19 25 32 44
62

14. FEA Simulation SPF vs OESPF AA5083
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 5 10 15 20 25 30 35 40 45 50 55 60
Pressure
(Psi)
Strain
rate
(1/second)
Time (seconds)
60
Limit
SPF
60
60
16 19 25 32 44
62
0
50
100
150
200
250
300
350
400
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 5 10 15 20 25 30 35 40 45 50 55 60
Pressure
(Psi)
Strain
rate
(1/second)
Time (seconds)
60
Limit
SPF
32
44
62
25
16
19
16 19 25 32 44
62
Limit
OESPF

15. FEA Simulation AA5083 1.4 mm Thickness
SPF
240 seconds forming time
54% thickness reduction
0.1/s Peak Strain Rate
SPF
300 seconds forming time
45% thickness reduction
0.05/s Peak Strain Rate
54 %
45 %
OESPF
16 seconds forming time
43% thickness reduction
0.16/s Peak Strain Rate
43 %
OESPF more uniform
thickness distribution

16. FEA Simulation – Maximum Von Mises Stress
OESPF
16 seconds forming time
0.16/s Peak Strain Rate
SPF
300 seconds forming time
0.05/s Peak Strain Rate
OESPF
part formed at
lower stresses
higher strain rates
74 MPa
83 MPa

17. FEA Simulation Summary AA5083
OESPF SPF
Time to reach 50% thickness
OESPF process improves material grain boundary sliding mechanism
through in Process Dynamic Stress Relieve leading to more homogenous
stress distribution with the following potential benefits:
• reduces forming time
• increases elongation
• improves thickness uniformity
• reduces localized peak stresses
• operate at higher strain rates
• more economical process
- 16 sec 250 - 300 sec

18. Thank You!
Contact Info:
Kevin Fernandes
President
Macrodyne Technologies Inc.
www.macrodynepress.com
905 669 2253 x 301
kfernandes@macrodynepress.com