Magnetic Pulse Forming of Thin-Aluminum Sheet Using Bar-Forming Coil

2011 ◽  
Vol 337 ◽  
pp. 621-624 ◽  
Author(s):  
Ji Yeon Shim ◽  
Ill Soo Kim ◽  
Dong Hwan Park ◽  
Bong Yong Kang
Keyword(s):  
Intelligent System ◽  
Analysis Data ◽  
Aluminum Sheet ◽  
Design Parameters ◽  
Fe Model ◽  
Magnetic Pulse ◽  
Forming Process ◽  
Thin Aluminum ◽  
Magnetic Pulse Forming ◽  
Measured Strain

Generally a MPF(Magnetic pulse forming) process refers to the high velocity and high strain rate deformation of a low-ductility materials driven by electromagnetic forces that are generated by the rapid discharge current through the forming coil. The goal of this study was to investigate the main design parameter in MPF. To achieve the above objectives, An intelligent system which consisted of thin 5053 aluminum sheet and bar forming coil was employed for the experiment. The measured strain data have been analyzed using the developed electromagnetic FE-model. The analysis data showed that the uniform electromagnetic force is one of most important design parameters in MPF process.

Development of Electromagnetic-Mechanical Coupled FE-Model for Thin Aluminum Plate Forming Using Electromagnetic Force

2013 ◽  
Vol 535-536 ◽  
pp. 267-270 ◽  
Author(s):  
Ji Yeon Shim ◽  
Young Choi ◽  
Bong Yong Kang
Keyword(s):  
Electromagnetic Force ◽  
Coupled Model ◽  
Aluminum Plate ◽  
Fe Model ◽  
Magnetic Pulse ◽  
Coil Design ◽  
Electromagnetic Model ◽  
Thin Aluminum ◽  
Magnetic Pulse Forming ◽  
Manufacturing Time

The high cost of manufacturing and manufacturing time is required for preliminary experiment by manufacturing various type of coil every time for the forming of the required shape, it is essentially required to develop the coil design technology using a FEM. Thus, in order to form the required shape, it is important to design the coil using a FEM and predict the final forming product. Therefore, in this study developed electro-mechanical coupled FE-model for thin aluminum plate forming using electromagnetic force. In order to carry out this, magnetic pulse forming was carried by electromagnetic forming system total energy of 24kJ. Peck current and discharge speed acquired through magnetic pulse forming experiment using Rogowski current waveform transducer was used as input data in electromagnetic FE-model. Then, calculated electromagnetic force between forming coil and workpiece through the developed electromagnetic model was inputted as a load of mechanical FE-model for the prediction of thin aluminum plate forming shape. As results, developed electromagnetic-mechanical coupled model shall be able to be usefully used when designing the forming coil to secure the required forming shape later.

Development of FE-Model for Al 5053 Sheet Plate Forming Using Electromagnetic Force

2011 ◽  
Vol 335-336 ◽  
pp. 1099-1102 ◽  
Author(s):  
Ji Yeon Shim ◽  
Ill Soo Kim ◽  
Ji Hye Lee ◽  
In Ju Kim ◽  
Bong Yong Kang
Keyword(s):  
Research Area ◽  
Fe Model ◽  
Magnetic Pulse ◽  
Plastic Working ◽  
Forming Process ◽  
3 Dimensional ◽  
Control Information ◽  
Magnetic Pulse Forming ◽  
Deformation Mechanics ◽  
Insight Into

Magnetic pulse forming is based on the principle of generation of a repulsive force called, Lorentz force due to opposing magnetic fields of adjacent conductors. Magnetic pulse forming of light weight materials such as aluminum, magnesium has been studied by many universities, institutes due to its advantages. But magnetic pulse forming is a complicated research area involving different topics in electromagnetic mechanics, plastic working, and materials mechanics. Therefore, development of FE-model of magnetic pulse forming process is a useful approach for better insight into workpiece deformation mechanics with electromagnetic interaction and further provides design and quality control information. To successfully accomplish this objective, a 3-dimensional ax-symmetric electromagnetic numerical model has been developed. The equation was solved using a general mechanics computer program, ANSYS EMAG and LS-DYNA code.

Optimizing Roll Forming Processes with the Aid of a New Numerical Algorithm

2012 ◽  
Vol 504-506 ◽  
pp. 857-862 ◽  
Author(s):  
Ahmad Abrass ◽  
Thomas Kessler ◽  
Peter Groche
Keyword(s):  
Numerical Algorithm ◽  
Numerical Algorithms ◽  
Roll Forming ◽  
Design Parameters ◽  
Fe Model ◽  
Forming Process ◽  
Cross Sectional ◽  
Cross Sectional Profile ◽  
Sectional Profile ◽  
Roll Forming Process

For the manufacturing of large quantities of profile-shaped products, the roll forming process represents one of the most effective metal forming technologies. During this process, the sheet metal will be formed into a desired cross-sectional profile using successive pairs of forming rolls. This process is well known as a very complex process in industry because of the multiplicity of the process and design parameters. For that reason, the optimization of roll forming processes using numerical methods like the finite element method is very complex and time-consuming. In this paper, a numerical method will be introduced to accelerate the simulation and to optimize the roll forming process. The newly developed algorithm will be illustrated and validated by analyzing the roll forming process. The details of the FE-model and the numerical algorithm will be described. Furthermore, the results of the numerical simulation with and without the application of the numerical algorithms will be compared. Finally, the process will be optimized using the newly developed method.

scholarly journals Experimental and Numerical Analyses of Magnetic Pulse Forming of A1050 Aluminum Sheet

2020 ◽  
Vol 61 (2) ◽  
pp. 346-354
Author(s):  
Takashi Kambe ◽  
Yasutaka Kedo ◽  
Shinji Muraishi ◽  
Shinji Kumai
Keyword(s):  
Numerical Analyses ◽  
Aluminum Sheet ◽  
Magnetic Pulse ◽  
Magnetic Pulse Forming

Determination of High Strain-Rate Behavior of Metals: Applications to Magnetic Pulse Forming and Electrohydraulic Forming

2014 ◽  
Vol 611-612 ◽  
pp. 643-649 ◽  
Author(s):  
Anne Claire Jeanson ◽  
Gilles Avrillaud ◽  
Gilles Mazars ◽  
Jean Paul Cuq-Lelandais ◽  
Francois Bay ◽  
...  
Keyword(s):  
Strain Rate ◽  
Tensile Tests ◽  
Expansion Velocity ◽  
Magnetic Pulse ◽  
Constitutive Behaviour ◽  
Forming Process ◽  
Electrohydraulic Forming ◽  
Workpiece Material ◽  
Magnetic Pulse Forming ◽  
Static Conditions

The design of processes like magnetic pulse forming and electrohydraulic forming involves multiphysical couplings that require numerical simulation, and knowledge on dynamic behaviour of metals. The forming process is completed in about 100 μs, so that the workpiece material deforms at strain-rates between 100 and 10 000 s-1. In this range, the mechanical behaviour can be significantly different than that in quasi-static conditions. It is often noticed that the strength and the formability are higher. The main goal of this study is to use an electromagnetically driven test on tubes or sheets to identify the constitutive behaviour of the workpiece material. In the case of tube, an industrial helix coil is used as inductor. Simulations with the code LS-Dyna® permit to find a configuration where the tube deforms homogeneously enough to allow axisymmetric modelling of the setup. The coil current is measured and used as an input for the simulations. The radial expansion velocity is measured with a Photon Doppler Velocimeter. The parameter identification is lead with the optimization software LS-Opt®. LS-Dyna axisymmetric simulations are launched which different set of parameters for the constitutive behaviour, until the computed expansion velocity fits the experimental velocity. The optimization algorithm couples a gradient method and a global method to avoid local minima. Numerical studies show that for the Johnson-Cook constitutive model, two or three experiments at different energies are required to identify the expected parameters. The method is applied to Al1050 tubes, as received and annealed. The parameters for the Johnson-Cook and Zerilli-Armstrong models are identified. The dynamic constitutive behaviour is compared to that measured on quasi-static tensile tests, and exhibits a strong sensitivity to strain-rate. The final strains are also significantly higher at high velocity, which is one of the major advantages of this kind of processes.

scholarly journals Modeling of thin sheet forming processes by combining solid-shell finite element with isotropic elastoviscoplastic model. Application to magnetic pulse forming processes

2021 ◽  
Author(s):  
Mohamed Mahmoud ◽  
François Bay ◽  
Daniel Pino Mũnoz
Keyword(s):  
Sheet Metal ◽  
Thin Sheet ◽  
Magnetic Pulse ◽  
Solid Shell ◽  
Forming Process ◽  
Thin Structures ◽  
Shell Elements ◽  
Tetrahedral Element ◽  
Magnetic Pulse Forming ◽  
Assumed Strain

Sheet metal alloys are used in many industries to save material, reduce weight and improve the overall performance of products. For the last decades, many types of elements have been developed to resolve the locking problems encountered in the simulation of thin structures. Among these approaches, a family of assumed-strain solid-shell elements has proved to be very efficient and attractive in simulating thin 3D structures with various constitutive models. Furthermore, these elements are able to account for anisotropic behavior of thin structures since isotropic yield functions cannot capture the real physics of some forming processes. In this work, von Mises isotropic yield criterion with Johnson-cook hardening model are combined with a linear prismatic solid-shell element to simulate sheet metal forming processes. A new element assembly technique has been developed to permit the assembly of prismatic elements in a tetrahedral element-based software. This technique splits the prism into multiple tetrahedral elements in such a way that all the cross-terms are accounted for. Furthermore, a tetrahedral based partitioning code has been modified to account for the new prismatic element shape without changing the core structure of the code. More accurate results were obtained using low number of solid-shell elements compared to its counterpart tetrahedral element (MINI element). This reduction in the number of elements accelerated the simulation, especially in the coupled magnetic-structure simulation used for magnetic pulse forming process. The proposed element and criteria are implemented into FORGE (in-house code developed at CEMEF) for simulating magnetic pulse forming process.

Constitutive Relationship of 3A21 Aluminium Alloy Tube for Magnetic Pulse Forming

2012 ◽  
Vol 239-240 ◽  
pp. 314-319
Author(s):  
Zhi Dan Xu ◽  
Jun Jia Cui ◽  
Hai Ping Yu ◽  
Chun Feng Li
Keyword(s):  
Constitutive Equation ◽  
Aluminium Alloy ◽  
Split Hopkinson Pressure Bar ◽  
Constitutive Relationship ◽  
Dynamic State ◽  
Magnetic Pulse ◽  
Forming Process ◽  
Alloy Tube ◽  
Magnetic Pulse Forming ◽  
Aluminum Alloy Tube

In this work, Split Hopkinson Pressure Bar (SHPB) was employed to test the material properties dynamic forming. The stress-strain curves and dynamic yield strengths under variable strain rates were obtained. Constitutive equation of 3A21 aluminium alloy was formulated by Johnson-Cook model and then, it was applied to simulate the forming behavior of 3A21 aluminum alloy tube under dynamic state by software Ansys/ls-dyna. The results show that, for magnetic pulse forming process, the simulating results well corresponded with those of experiments that demonstrate the constitutive equation established present good accuracy.

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