Analytical optimization on geometry of uniform pressure coil in electromagnetic forming and welding

2019 ◽  
Vol 104 (5-8) ◽  
pp. 3129-3137 ◽  
Author(s):  
Zhipeng Lai ◽  
Quanliang Cao ◽  
Xiaotao Han ◽  
Liang Li
Keyword(s):  
Electromagnetic Forming ◽  
Uniform Pressure ◽  
Uniform Pressure Coil

scholarly journals Electromagnetic Sheet Forming by Uniform Pressure Using Flat Spiral Coil

Materials ◽  
2019 ◽  
Vol 12 (12) ◽  
pp. 1963 ◽  
Author(s):  
Xiaohui Cui ◽  
Dongyang Qiu ◽  
Lina Jiang ◽  
Hailiang Yu ◽  
Zhihao Du ◽  
...  
Keyword(s):  
Service Life ◽  
Magnetic Force ◽  
Electromagnetic Forming ◽  
Force Distribution ◽  
Manufacturing Cost ◽  
Main Process ◽  
Uniform Pressure ◽  
Spiral Coil ◽  
Uniform Pressure Coil ◽  
Simulation Results

The coil is the most important component in electromagnetic forming. Two important questions in electromagnetic forming are how to obtain the desired magnetic force distribution on the sheet and increase the service life of the coil. A uniform pressure coil is widely used in sheet embossing, bulging, and welding. However, the coil is easy to break, and the manufacturing process is complex. In this paper, a new uniform-pressure coil with a planar structure was designed. A three-dimensional (3D) finite element model was established to analyze the effect of the main process parameters on magnetic force distribution. By comparing the experimental results, it was found that the simulation results have a higher analysis precision. Based on the simulation results, the resistivity of the die, spacing between the left and right parts of the coil, relative position between coil and sheet, and sheet width significantly affect the distribution of magnetic force. Compared with the structure and magnetic force on a traditional uniform pressure coil, the planar uniform pressure coil can produce a uniform magnetic force distribution on the sheet, reduce the manufacturing difficulty, reduce manufacturing cost, and enhance the service life for the coil.

Dual Electromagnetic Forming Using Single Uniform Pressure Coil

2014 ◽  
Vol 611-612 ◽  
pp. 723-730
Author(s):  
Chandrahas Patel ◽  
Sachin D. Kore
Keyword(s):  
High Speed ◽  
Bottom Layer ◽  
Electromagnetic Forming ◽  
Uniform Pressure ◽  
Forming Process ◽  
Electrically Conductive ◽  
Maximum Deformation ◽  
Uniform Pressure Coil ◽  
High Speed Forming ◽  
Sheet Metal Workpiece

Electromagnetic Forming (EMF) is a high-speed forming process that can be applied for shaping, joining and cutting of workpieces made of electrically conductive material eg. aluminium. This paper proposes a dual electromagnetic forming method. Energy efficiency of the dual electromagnetic forming is compared with the single sided electromagnetic forming using FEM simulations. In uniform pressure rectangular coil, the top layer of the coil assists in the deformation of the workpiece while the bottom layer hinders the workpiece deformation.To make the bottom layer of the coil also to assist in the deformation of the workpiece, a uniform pressure rectangular coil is designed and placed between the two sheet metal workpiece. The efficiency of the two processes are compared by determing the maximum deformation obtained for each case.

Coil-less electromagnetic forming process with uniform-pressure characteristics for shaping sheet metals

2021 ◽  
Vol 70 ◽  
pp. 140-151
Author(s):  
Quanliang Cao ◽  
Xian Li ◽  
Zhenhao Li ◽  
Limeng Du ◽  
Liangyu Xia ◽  
...  
Keyword(s):  
Electromagnetic Forming ◽  
Uniform Pressure ◽  
Sheet Metals ◽  
Forming Process ◽  
Pressure Characteristics

Analytical Design and Implementation of a Uniform Pressure Actuator for Electromagnetic Forming and Welding

2013 ◽  
Author(s):  
E. Thibaudeau ◽  
B. L. Kinsey
Keyword(s):  
Sheet Metal ◽  
Analytical Modeling ◽  
Electromagnetic Forming ◽  
Design Parameters ◽  
Magnetic Pulse ◽  
Uniform Pressure ◽  
Coil Design ◽  
Element Analysis ◽  
The Ohio State University ◽  
Pulse Welding

Lightweight sheet metal components and assemblies formed and welded electromagnetically can be implemented in various industries such as automotive, aerospace, and electronics. Past applications and modeling of Electromagnetic Forming (EMF) and Magnetic Pulse Welding (MPW) have typically focused on crimping and expansion of tubular workpieces. While some Finite Element Analysis (FEA) packages exist that are capable of modeling these processes, there is a lack of simplified analytical modeling efforts, especially for sheet metal workpieces. Analytical modeling is attractive for its simplicity and cost in effectively determining e.g., an optimal coil design. In this paper a coil design and analysis procedure developed at The Ohio State University is modified and extended through an analytical model and FEA. The coil, named a Uniform Pressure Actuator (UPA), offers increased forming efficiency and repeatability, as well as a robust design. Coil design parameters such as the number of turns and conductor cross section are determined for a given workpiece. Magnetic pressure applied to the workpiece and workpiece velocity are predicted to ensure impact velocities are sufficient for MPW. A coil was constructed based on the analyses, and experimental results are compared to the analytical predictions for both electrical characteristics and workpiece velocity.

scholarly journals A Uniform Pressure Electromagnetic Actuator for Forming Flat Sheets

2006 ◽  
Vol 129 (2) ◽  
pp. 369-379 ◽  
Author(s):  
Manish Kamal ◽  
Glenn S. Daehn
Keyword(s):  
Spatial Distribution ◽  
Robust Design ◽  
High Velocity ◽  
High Efficiency ◽  
Electromagnetic Forming ◽  
Electromagnetic Actuator ◽  
Uniform Pressure ◽  
Flat Sheet ◽  
New Type ◽  
Simplified Analysis

High velocity electromagnetic forming can lead to better formability along with additional benefits. The spatial distribution of forming pressure in electromagnetic forming can be controlled by the configuration of the actuator. A new type of actuator is discussed which gives a uniform pressure distribution in forming. It also provides a mechanically robust design and has a high efficiency for flat sheet forming. A simplified analysis of the actuator is presented that helps in the design of the system. Examples of uses of the actuator are then presented, specifically with regards to forming shapes and surface embossing. Some practical challenges in the design of the actuator are also addressed. This paper emphasizes the approaches and engineering calculations required to effectively use this actuator.

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