Fully Coupled Numerical Simulation of Electromagnetic Forming

2012 ◽  
Vol 504-506 ◽  
pp. 1201-1206 ◽  
Author(s):  
Jyoti Kumar Doley ◽  
Sachin D. Kore
Keyword(s):  
Numerical Simulation ◽  
High Speed ◽  
Simulation Method ◽  
Electromagnetic Forming ◽  
Structural Deformation ◽  
Forming Process ◽  
Finite Element Software ◽  
Metal Forming Process ◽  
High Speed Forming ◽  
Fully Coupled

Electromagnetic forming (EMF) is a typical high speed forming process using the energy density of a pulsed magnetic field to form work pieces made of metals with high electrical conductivity like aluminum. In view of new lightweight constructions, special forming processes like EMF gain importance for the associated materials. In this paper modeling of electromagnetic sheet metal forming process is carried out by using commercial finite element software LS-DYNA®. A fully coupled numerical simulation method has been incorporated to study the interaction of the electromagnetic field and the structural deformation via transient analysis. Studies on the effect of first current pulse in electromagnetic forming are reported in the paper.

Electromagnetic Formability of an Aluminium Ice Tray

2014 ◽  
Vol 611-612 ◽  
pp. 1124-1131 ◽  
Author(s):  
Jyoti Kumar Doley ◽  
Sachin D. Kore
Keyword(s):  
Strain Rate ◽  
High Speed ◽  
Paper Analysis ◽  
Electromagnetic Forming ◽  
Forming Process ◽  
Spiral Coil ◽  
Finite Element Software ◽  
Metal Forming Process ◽  
Sequential Coupling ◽  
Explosive Forming

Electromagnetic forming (EMF) is a typical high speed forming process using the energy density of a pulsed magnetic field to form work sheets made of metals with high electrical conductivity like aluminium alloys, which have low formability at low strain rate. Under high velocity forming, metallic materials exhibit an increase of flow stress and ductility with increasing deformation rate. Therefore, materials of lower ductility can be deformed to higher strains using high strain rate deformation processes such as electromagnetic or explosive forming techniques. In this paper analysis of an electromagnetic sheet metal forming process is carried out by using commercial finite element software LS-DYNA®, which incorporates a sequential coupling method involving electromagnetic field, structural and thermal solutions. Study of process parameters for forming aluminium ice tray (used in refrigerator) by Electromagnetic forming process has been carried out, simulation was done involving a die, Al worksheet and a spiral coil.

Joining of Tubular Parts by Electromagnetic Forming; Experimental Investigations

2014 ◽  
Vol 792 ◽  
pp. 115-120 ◽  
Author(s):  
Pál Rácz ◽  
Nándor Göbl ◽  
Daniel Horváth ◽  
Athanasios G. Mamalis
Keyword(s):  
High Speed ◽  
New Technologies ◽  
Dissimilar Materials ◽  
High Energy ◽  
Mechanical Tests ◽  
Electromagnetic Forming ◽  
High Energy Density ◽  
Experimental Investigations ◽  
Forming Process ◽  
High Speed Forming

Electromagnetic forming is a high speed forming process, wherein the forming pressure is created by high energy density electromagnetic pulse. Besides direct shaping there are other application areas as well, so electromagnetic plastic forming is a potential field of creating joints between tube and rod-like components. Connecting components of dissimilar materials is an increasing demand in the manufacturing process of structures in the automotive industry. The application of new technologies, such as electrodynamic, especially electromagnetic forming, is a possible method to satisfy these demands. The article summarizes the most important fundamentals of electromagnetic forming; in particular, tube-rod joints, the main types of such joints; interference-fit and form-fit joints are described. Experiments, which were carried out producing tube-rod joints with electromagnetic forming, are also introduced. A new type of form-fit joints for tube-rod connections has been developed, which can withstand not only tensile loads but also torsion. Experiments and mechanical tests have proved the applicability of this kind of joints.

Electromagnetic Sheet Bulging: Analysis of Process Parameters by FE Simulations

2013 ◽  
Vol 554-557 ◽  
pp. 741-748 ◽  
Author(s):  
Joao Pedro M. Correia ◽  
Saïd Ahzi
Keyword(s):  
Finite Element ◽  
Process Parameters ◽  
High Speed ◽  
Finite Element Simulations ◽  
Electromagnetic Forming ◽  
Forming Process ◽  
High Speed Forming ◽  
Bulging Test ◽  
High Repeatability

Electromagnetic forming is a non-conventional forming process and is classified as a high-speed forming process. It provides certain advantages as compared to conventional forming processes: improved formability, high repeatability and productivity, reduction in tooling cost and reduction of springback and of wrinkling. However, various process parameters affect the performance of the electromagnetic forming system. Finite element simulations are very useful to optimize a process because they can reduce time and costs. With the aim of investigating the effects of the process parameters on the deformed blank geometry, finite element simulations of an electromagnetic sheet bulging test have been performed in this work. Furthermore the role of first impulse of discharged current is also investigated.

Study of Electromagnetic Forming Process on Tubular Components

2014 ◽  
Vol 592-594 ◽  
pp. 894-898
Author(s):  
K. Sriram ◽  
Karibeeran Shanmuga Sundaram ◽  
P. Arumugam
Keyword(s):  
High Speed ◽  
Electromagnetic Forming ◽  
Work Piece ◽  
Forming Process ◽  
Compression Process ◽  
Aluminium Copper ◽  
High Speed Forming ◽  
Set Up ◽  
Tubular Components ◽  
Forming Methods

Forming processes are defined as to modify the shape of a work piece by deforming it, without the removal of material. To overcome a number of longstanding problems in conventional forming methods such as low production rates, difficulty in forming light weight components etc., an alternate approach of electromagnetic forming process is introduced. Electromagnetic forming (EMF) is a high speed forming process used to form thinwalled work pieces (usually sheets and tubes) that have high electrical conductivity, such as aluminium, copper etc. Electromagnetic tube compression processes, the design of an experimental set up for electromagnetic tube compression process are discussed in detail in this paper

Numerical and Experimental Investigation of Inward Tube Electromagnetic Forming- Electromagnetic Study

2011 ◽  
Vol 383-390 ◽  
pp. 6710-6716 ◽  
Author(s):  
Alireza Fallahi Arezoodar ◽  
Hossein Ebrahimi Haratmeh ◽  
Mohmoud Farzin
Keyword(s):  
Numerical Simulation ◽  
Experimental Investigation ◽  
Process Parameters ◽  
High Speed ◽  
Discharge Voltage ◽  
Electromagnetic Forming ◽  
Experimental Results ◽  
Electromagnetic Parameters ◽  
High Speed Forming ◽  
Structural Parts

A numerical simulation of high-speed forming of tubes on the die in electromagnetic forming (EMF) system is presented to study effects of some electromagnetic parameters. Simulations of electromagnetic and structural parts of EMF process are carried out. Calculated currents in this process are in agreement with experimental results measured by Rogowsky coil. But calculated and simulated currents at first peak are a little more than the experimental value. Effects of material and process parameters on bead depth are investigated in detail with this validated code. It deduced that shape of the bead is affected by discharge voltage and coil parameters. As a result, the bead depth increases with the increase of the discharge voltage and decrease of number of windings.

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.

An Analysis of Electromagnetic Sheet Metal Forming Process

2014 ◽  
Vol 526 ◽  
pp. 9-14 ◽  
Author(s):  
E. Paese ◽  
Pedro A.R. Rosa ◽  
Martin Geier ◽  
Roberto P. Homrich ◽  
R. Rossi
Keyword(s):  
Sheet Metal Forming ◽  
Metal Forming ◽  
High Speed ◽  
Flat Plates ◽  
Forming Process ◽  
Spiral Coil ◽  
Metal Forming Process ◽  
High Speed Forming ◽  
Flat Spiral ◽  
Free Bulging

Electromagnetic forming (EMF) is a high-speed forming process that uses energy density of a pulsed magnetic field to deform metallic workpieces. This paper presents a method to calculate the electromagnetic force in thin flat plates using a flat spiral coil as an actuator. The method is based on the Biot-Savart law, and the solution of magnetic induction integral equations is performed inside Matlab®by a numerical method based on discretizing the EMF system in a system of ordinary differential equations that couple the electric and magnetic phenomena. Free bulging experiments and a comparison with Ansoft Maxwell®software are presented demonstrating a good correlation with the proposed implementation.

Wrinkling Prediction and Optimization of Sheet Metal Forming Process by Numerical Simulation

2015 ◽  
Vol 818 ◽  
pp. 252-255 ◽  
Author(s):  
Ján Slota ◽  
Marek Šiser
Keyword(s):  
Numerical Simulation ◽  
Material Model ◽  
Mechanical Tests ◽  
Simulation Software ◽  
Forming Process ◽  
Part Geometry ◽  
Nominal Thickness ◽  
430 Stainless Steel ◽  
Metal Forming Process ◽  
Aisi 430

The paper deals with optimization of forming process for AISI 430 stainless steel with nominal thickness 0.4 mm. During forming of sidewall for washing machine drum, some wrinkles remain at the end of forming process in some places. This problem was solved by optimization the geometry of the drawpiece using numerical simulation. During optimization a series of modifications of the part geometry to absolute elimination of wrinkling was performed. On the basis of mechanical tests, the material model was created and imported into the material database of Autoform simulation software.

scholarly journals Numerical Simulation for Engine/Airframe Interaction Effects of the BWB300 on Aerodynamic Performances

2019 ◽  
Vol 2019 ◽  
pp. 1-15 ◽  
Author(s):  
Gang Yu ◽  
Dong Li ◽  
Yue Shu ◽  
Zeyu Zhang
Keyword(s):  
Numerical Simulation ◽  
High Speed ◽  
Separated Flow ◽  
Simulation Method ◽  
Interaction Effects ◽  
Surface Flow ◽  
Concept Design ◽  
Aerodynamic Forces ◽  
Low Speed ◽  
Aerodynamic Performances

The engine/airframe interaction effects of the BWB300 on aerodynamic performances were analyzed by using the numerical simulation method. The BWB300 is a 300-seat Blended Wing Body airplane designed by the Airplane Concept Design Institute of Northwestern Polytechnical University. The engine model used for simulation was simplified as a powered nacelle. The results indicated the following: at high speed, although the engine/airframe interaction effects on the aerodynamic forces were not significant, the airframe’s upper surface flow was greatly changed; at low speed, the airframe’s aerodynamic forces (of the airplane with/without the engine) were greatly different, especially at high attack angles, i.e., the effect of the engine suction caused the engine configuration aerodynamic forces of the airframe to be bigger than those without the engine; and the engine’s installation resulting in the different development of flow separation at the airframe’s upper surface caused greater obvious differences between the 2 configurations at high angles and low speed. Moreover, at low-speed high attack angles, the separated flow from the blended area caused serious distortion at the fan inlet of the engine.

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