Dual Electromagnetic Forming Using Single Uniform Pressure Coil

2014 ◽  
Vol 611-612 ◽  
pp. 723-730
Author(s):  
Chandrahas Patel ◽  
Sachin D. Kore

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.

2014 ◽  
Vol 792 ◽  
pp. 115-120 ◽  
Author(s):  
Pál Rácz ◽  
Nándor Göbl ◽  
Daniel Horváth ◽  
Athanasios G. Mamalis

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.


2013 ◽  
Vol 554-557 ◽  
pp. 741-748 ◽  
Author(s):  
Joao Pedro M. Correia ◽  
Saïd Ahzi

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.


2014 ◽  
Vol 592-594 ◽  
pp. 894-898
Author(s):  
K. Sriram ◽  
Karibeeran Shanmuga Sundaram ◽  
P. Arumugam

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


2012 ◽  
Vol 504-506 ◽  
pp. 1201-1206 ◽  
Author(s):  
Jyoti Kumar Doley ◽  
Sachin D. Kore

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.


2021 ◽  
Vol 70 ◽  
pp. 140-151
Author(s):  
Quanliang Cao ◽  
Xian Li ◽  
Zhenhao Li ◽  
Limeng Du ◽  
Liangyu Xia ◽  
...  

Materials ◽  
2019 ◽  
Vol 12 (12) ◽  
pp. 1963 ◽  
Author(s):  
Xiaohui Cui ◽  
Dongyang Qiu ◽  
Lina Jiang ◽  
Hailiang Yu ◽  
Zhihao Du ◽  
...  

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.


2019 ◽  
Vol 290 ◽  
pp. 03010
Author(s):  
Dorin Luca ◽  
Cristina Biriş ◽  
Dorian Luca

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.


2013 ◽  
Vol 554-557 ◽  
pp. 2363-2368 ◽  
Author(s):  
Yalin Kiliclar ◽  
O. Koray Demir ◽  
Ivaylo N. Vladimirov ◽  
Lukas Kwiatkowski ◽  
Stefanie Reese ◽  
...  

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.


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