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.

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.

Research on Workpiece Deformation in Electromagnetic Forming Process with Finite Element Method

2014 ◽  
Vol 989-994 ◽  
pp. 2702-2704
Author(s):  
Chang Peng ◽  
Li Qiu ◽  
Ke Shen Gong ◽  
Ding Jun Wang
Keyword(s):  
Electromagnetic Coupling ◽  
Basic Structure ◽  
Electromagnetic Forming ◽  
Forming Process ◽  
Spiral Coil ◽  
Electromagnetic Structure ◽  
Sequential Coupling ◽  
Flat Spiral ◽  
Free Bulging ◽  
Center Area

Electromagnetic forming is a kind of processing technology that use lorentz force to make rapid prototyping of metal workpiece, which can significantly improve the metal forming performance,and it is expected to become an emerging technology that alternative to traditional machining to process light alloy materials. Based on the understanding the basic structure of the electromagnetic coupling on the basis of physical process of electromagnetic forming, this article adopt ANSYS sequential coupling method to simulate the electromagnetic coupling process of electromagnetic structure, and analysis of tube electromagnetic forming and plate of workpiece in the process of free bulging deformation behavior. The solenoid coil tubing have an axis of symmetry due to bulging, and it’s electromagnetism load and constraint has symmetry, so its formability is uniform in hoop direction. When the plank free bulge, the distribution of the electromagnetic force caused by the flat spiral coil is not uniform,and the artifacts accelerate fastest in the part of the radius of coil 1/2, but the center area of the workpiece’s forming height is highest.

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.

scholarly journals Springback Calibration of a U-Shaped Electromagnetic Impulse Forming Process

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 603 ◽  
Author(s):  
Xiaohui Cui ◽  
Zhiwu Zhang ◽  
Hailiang Yu ◽  
Xiaoting Xiao ◽  
Yongqi Cheng
Keyword(s):  
Tangential Stress ◽  
Three Dimensional ◽  
Element Model ◽  
Simulation Method ◽  
Discharge Voltage ◽  
Electromagnetic Forming ◽  
Forming Process ◽  
Sheet Bending ◽  
Sequential Coupling ◽  
Good Agreement

A three-dimensional (3D) finite-element model (FEM), including quasi-static stamping, sequential coupling for electromagnetic forming (EMF) and springback, was established to analyze the springback calibration by electromagnetic force. Results show that the tangential stress at the sheet bending region is reduced, and even the direction of tangential stress at the bending region is changed after EMF. The springback can be significantly reduced with a higher discharge voltage. The simulation results are in good agreement with the experiment results, and the simulation method has a high accuracy in predicting the springback of quasi-static stamping and electromagnetic forming.

Numerical Simulation of Eccentric Explosive Forming Using Cylindrical Pressure Vessel

2012 ◽  
Author(s):  
Hirofumi Iyama ◽  
Shigeru Itoh
Keyword(s):  
Numerical Simulation ◽  
Shock Wave ◽  
Metal Forming ◽  
Metal Plate ◽  
Forming Process ◽  
Underwater Shock Wave ◽  
Metal Forming Process ◽  
Underwater Shock ◽  
Explosive Forming ◽  
Free Metal

Explosive forming is one of the effective metal forming methods using underwater shock wave generated by the detonation of an explosive. The experiment of eccentric spherical free metal forming by this method was carried out. This free metal forming process does not use require expensive metal die. We used simple metal die with only circular edges and considered the metal plate formed to required shape using this method. It was possible to change the pressure distribution applied on the metal plate by changing the set-up position of the explosive and the shape of the device. We have considered this method to cause lessen cost in the small production by various types of metal forming process. In this paper, we introduce the method of eccentric spherical free metal forming using underwater shock wave and present the experimental results. The numerical simulation on this method by FDM (Finite Difference Method) was carried out. In this paper, those results are discussed.

scholarly journals Electromagnetic Forming Analysis of the Al 99.0 Sheet with Tools of Different Configurations

2019 ◽  
Vol 290 ◽  
pp. 03010
Author(s):  
Dorin Luca ◽  
Cristina Biriş ◽  
Dorian Luca
Keyword(s):  
Electromagnetic Forming ◽  
Forming Process ◽  
Spiral Coil ◽  
Maximum Deformation ◽  
Manufacturing Procedure ◽  
Forming Analysis ◽  
Deformation Force ◽  
Spiral Coils ◽  
Flat Spiral ◽  
The Mathematical Model

Electromagnetic forming is an advanced manufacturing procedure, characterized by the fact that the tool carrying the deformation force does not touch the workpiece. This paper presents research regarding the electromagnetic forming of Al 99.0 (EN AW-1200) sheet with coils, having different configurations. The purpose of the research was to find the flat spiral coil configuration that ensures maximum deformation of the workpiece. Flat spiral coils with different gaps between the coil and the workpiece, and coils with different number of windings were tested. The influence of these parameters was monitored on the maximum strain of the free bulged parts. The analysis of the results obtained for different configurations of the flat spiral coils allowed the selection of the significant parameters that influenced the electromagnetic forming process of the Al 99.0 flat workpiece, which aimed to elaborate the mathematical model and to optimize the investigated process.

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.

Simulation of Electromagnetic Forming of a Cross-Shaped Cup by Means of a Viscoplasticity Model Coupled with Damage at Finite Strains

2013 ◽  
Vol 554-557 ◽  
pp. 2363-2368 ◽  
Author(s):  
Yalin Kiliclar ◽  
O. Koray Demir ◽  
Ivaylo N. Vladimirov ◽  
Lukas Kwiatkowski ◽  
Stefanie Reese ◽  
...  
Keyword(s):  
Finite Element ◽  
Deep Drawing ◽  
High Speed ◽  
Kinematic Hardening ◽  
Plastic Anisotropy ◽  
Deformation Gradient ◽  
Electromagnetic Forming ◽  
Isotropic Hardening ◽  
Order Structure ◽  
Forming Process

In the field of sheet metal forming traditional forming processes are used. However, a quasi-static forming process combined with a high speed forming process can enhance the forming limits of a single one. In this paper, the investigation of the process chain quasi-static deep drawing – electromagnetic forming by means of a new coupled damage-viscoplasticity model for large deformations is performed. The finite strain constitutive model, used in the finite element simulation combines nonlinear kinematic and isotropic hardening and is derived in a thermodynamically consistent setting. The anisotropic viscoplastic model is based on the multiplicative decomposition of the deformation gradient in the context of hyperelasticity. The kinematic hardening component represents a continuum extension of the classical rheological model of Armstrong–Frederick kinematic hardening. Hill-type plastic anisotropy is modelled by expressing the yield surface as a function of second-order structure tensors as additional tensor-valued arguments. The coupling of damage and plasticity is carried out in a constitutive manner according to the effective stress concept. The constitutive equations of the material model are integrated in an explicit manner and implemented as a user material subroutine in the commercial finite element package of LS-Dyna with the electromagnetical modul. Aim of the work is to show the increasing formability of the sheet by combining quasi-static deep drawing processes with high speed electromagnetic forming process.

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.

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