Electromagnetic Sheet Forming by Uniform Pressure Using Flat Spiral Coil

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.

Dual Electromagnetic Forming Using Single Uniform Pressure Coil

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.

Finite Element Method on Electromagnetic Shaping for Aluminum Alloy Sheet Parts

In this paper, the distribution of magnetic forces of uniform pressure coil and the electromagnetic shaping with die of aluminum alloy 1060 surface parts will be researched using the finite element method. The results show that: Uniform pressure coil can produce a uniform magnetic pressure on the sheet; The springback after electromagnetic aimed stamping is smaller than the springback after normal stamping; Before achieving the best results, with the discharge energy increases, springback will be smaller; with greater punch and die clearance, greater energy will be needed to achieve the best effect; Too large discharge energy will lead sheet bounce after punch, springback increases.