Electromagnetic forming and powder processing: Trends and developments

2004 ◽  
Vol 57 (4) ◽  
pp. 299-324 ◽  
Author(s):  
AG Mamalis and ◽  
DE Manolakos ◽  
AG Kladas ◽  
AK Koumoutsos
Keyword(s):  
Powder Processing ◽  
Industrial Applications ◽  
Electromagnetic Forming ◽  
Advanced Materials ◽  
Process Equipment ◽  
Magnetic Pulse ◽  
Forming Process ◽  
Compaction Of Powders ◽  
Pulse Welding ◽  
Physical Phenomena

A comprehensive review and assessment of the electromagnetic forming process is presented. Even though electromagnetic forming is a technology known for a few decades, renewed interest in it for industrial applications is currently taking place. Emphasis is mainly placed on the physical phenomena that govern the process as well as its main technological aspects, such as magnetic forming and joining, magnetic pulse welding, and dynamic magnetic compaction of powders. Moreover, some other important subjects concerning electromagnetic forming such as process equipment and workpiece formability are briefly presented in this paper. Applications of the process, mainly regarding manufacturing of advanced materials, are presented and discussed. This review article cites 149 references.

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.

A Novel Tool Design Strategy for Electromagnetic Forming

2014 ◽  
Vol 1018 ◽  
pp. 333-340 ◽  
Author(s):  
Reimund Neugebauer ◽  
Verena Psyk ◽  
Christian Scheffler
Keyword(s):  
Design Strategy ◽  
Tool Design ◽  
Electromagnetic Forming ◽  
Optimization Process ◽  
Magnetic Pulse ◽  
Preliminary Design ◽  
Magnetic Pulse Welding ◽  
Iterative Optimization ◽  
Industrial Manufacturing ◽  
Pulse Welding

To make the advantages of electromagnetic forming applicable for industrial manufacturing, a three step tool design strategy is suggested. At first, simplified decoupled electromagnetic and structural mechanical simulations are used for creating a preliminary design via a systematic iterative optimization process. The selected design is verified in more accurate coupled simulations. A prototypic realization serves for further optimization, if necessary. The applicability of the approach is proved on the basis of an inductor system for magnetic pulse welding of tubes.

scholarly journals Magnetic pulse welding on the cutting edge of industrial applications

2014 ◽  
Vol 19 (1) ◽  
pp. 69-81 ◽  
Author(s):  
R. M. Miranda ◽  
B. Tomás ◽  
T. G. Santos ◽  
N. Fernandes
Keyword(s):  
Magnetic Field ◽  
Solid State ◽  
High Speed ◽  
Industrial Applications ◽  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
Advantages And Disadvantages ◽  
Pulse Welding ◽  
The Impact ◽  
Very High

Magnetic Pulse Welding (MPW) applies the electromagnetic principles postulated in the XIXth century and later demonstrated. In recent years the process has been developed to meet highly demanding market needs involving dissimilar material joining, specially involving difficult-to-weld materials. It is a very high speed joining process that uses an electromagnetic force to accelerate one material against the other, resulting in a solid state weld with no external heat source and no thermal distortions. A high power source, the capacitor, a discharge switch and a coil constitute the minimum equipment necessary for this process. A high intensity current flowing through a coil near an electrically conductive material, locally produce an intense magnetic field that generates eddy currents in the flyer according to Lenz law. The induced electromotive force gives rise to a current whose magnetic field opposes the original change in magnetic flux. The effect of this secondary current moving in the primary magnetic field is the generation of a Lorentz force, which accelerates the flyer at a very high speed. If a piece of material is placed in the trajectory of the flyer, the impact will produce an atomic bond in a solid state weld. This paper discusses the fundamentals of the process in terms of phenomenology and analytical modeling and numerical simulation. Recent industrial applications are presented in terms of materials, joint configurations and real examples as well as advantages and disadvantages of the process.

Magnetic pulse welding of aluminum to steel tubes using a field-shaper with multiple seams

2021 ◽  
Vol 65 ◽  
pp. 214-227
Author(s):  
Ziqin Yan ◽  
Ang Xiao ◽  
Xiaohui Cui ◽  
Yuanzheng Guo ◽  
Yuhong Lin ◽  
...  
Keyword(s):  
Magnetic Pulse ◽  
Steel Tubes ◽  
Magnetic Pulse Welding ◽  
Pulse Welding

scholarly journals Statistical analysis of the reproducibility of residual stress measurements in cold extruded parts

2021 ◽  
Author(s):  
Fabian Jaeger ◽  
Alessandro Franceschi ◽  
Holger Hoche ◽  
Peter Groche ◽  
Matthias Oechsner
Keyword(s):  
Residual Stress ◽  
Statistical Analysis ◽  
Stress Measurement ◽  
Industrial Applications ◽  
Cold Extrusion ◽  
X Ray Diffraction ◽  
Forming Process ◽  
X Ray ◽  
Stress States ◽  
Key Aspects

AbstractCold extruded components are characterized by residual stresses, which originate from the experienced manufacturing process. For industrial applications, reproducibility and homogeneity of the final components are key aspects for an optimized quality control. Although striving to obtain identical deformation and surface conditions, fluctuation in the manufacturing parameters and contact shear conditions during the forming process may lead to variations of the spatial residual stress distribution in the final product. This could lead to a dependency of the residual stress measurement results on the relative axial and circumferential position on the sample. An attempt to examine this problem is made by the employment of design of experiments (DoE) methods. A statistical analysis of the residual stress results generated through X-Ray diffraction is performed. Additionally, the ability of cold extrusion processes to generate uniform stress states is analyzed on specimens of austenitic stainless steel 1.4404 and possible correlations with the pre-deformed condition are statistically examined. Moreover, the influence of the coating, consisting of oxalate and a MoS2 based lubricant, on the X-Ray diffraction measurements of the surface is investigated.

scholarly journals Analysis of Proximity Consequences of Coil Windings in Electromagnetic Forming

2021 ◽  
Vol 5 (2) ◽  
pp. 45
Author(s):  
Siddhant Prakash Goyal ◽  
Mohammadjavad Lashkari ◽  
Awab Elsayed ◽  
Marlon Hahn ◽  
A. Erman Tekkaya
Keyword(s):  
Proximity Effect ◽  
Experimental Methods ◽  
Electromagnetic Forming ◽  
Velocity Measurements ◽  
Local Curvature ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Geometrical Features ◽  
Physical Phenomena ◽  
Inverse Distance

Multiturn coils are required for manufacturing sheet metal parts with varying depths and special geometrical features using electromagnetic forming (EMF). Due to close coil turns, the physical phenomena of the proximity effect and Lorentz forces between the parallel coil windings are observed. This work attempts to investigate the mechanical consequences of these phenomena using numerical and experimental methods. A numerical model was developed in LS-DYNA. It was validated using experimental post-mortem strain and laser-based velocity measurements after and during the experiments, respectively. It was observed that the proximity effect in the parallel conductors led to current density localization at the closest or furthest ends of the conductor cross-section and high local curvature of the formed sheet. Further analysis of the forces between two coil windings explained the departure from the “inverse-distance” rule observed in the literature. Finally, some measures to prevent or reduce undesired coil deformation are provided.

Experimental investigation and optimization on field shaper structure parameters in magnetic pulse welding

2021 ◽  
pp. 095440542110148
Author(s):  
Yingzi Chen ◽  
Zhiyuan Yang ◽  
Wenxiong Peng ◽  
Huaiqing Zhang
Keyword(s):  
Magnetic Field ◽  
High Speed ◽  
Light Metal ◽  
Magnetic Pulse ◽  
Cross Sectional ◽  
Magnetic Pulse Welding ◽  
Pulse Welding ◽  
Sectional Shape ◽  
Welding System ◽  
The Magnetic Field

Magnetic pulse welding is a high-speed welding technology, which is suitable for welding light metal materials. In the magnetic pulse welding system, the field shaper can increase the service life of the coil and contribute to concentrating the magnetic field in the welding area. Therefore, optimizing the structure of the field shaper can effectively improve the efficiency of the system. This paper analyzed the influence of cross-sectional shape and inner angle of the field shaper on the ability of concentrating magnetic field via COMSOL software. The structural strength of various field shapers was also analyzed in ABAQUS. Simulation results show that the inner edge of the field shaper directly affects the deformation and welding effect of the tube. So, a new shape of field shaper was proposed and the experimental results prove that the new field shaper has better performance than the conventional field shaper.

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
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