Sheet metal electromagnetic forming using a flat spiral coil: Experiments, modeling, and validation

In this paper, we present a novel study on electromagnetic forming (EMF) comprises experiments, modeling, and validation. Free bulging of aluminum sheet metals was performed in an instrumented SMU1500 EMF machine for a range of energies using a custom-made die tool. Special regard is given to the de...

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Bibliographic Details
Published in:Journal of materials processing technology 2019-01, Vol.263, p.408-422
Main Authors: Paese, Evandro, Geier, Martin, Homrich, Roberto P., Rosa, Pedro, Rossi, Rodrigo
Format: Article
Language:English
Subjects:
Aluminum
Bulging
Computer simulation
Deformation
Electromagnetic forces
Electromagnetic forming
Electromagnetics
Experiments
Finite element method
Flat spiral coil
Force distribution
Magnetic field
Magnetic fields
Mathematical models
Metal sheets
Modelling
Search coil
Sheet metal
Stress concentration
Validation studies
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Summary:In this paper, we present a novel study on electromagnetic forming (EMF) comprises experiments, modeling, and validation. Free bulging of aluminum sheet metals was performed in an instrumented SMU1500 EMF machine for a range of energies using a custom-made die tool. Special regard is given to the description of the materials and methods in the experimental phase and in the validation of the proposed model during the modeling stage. An enhanced model that couples electrical and magnetic phenomena is proposed, aiming to compute the electromagnetic forces (which are subsequently used) into a mechanical uncoupled simulation, to predict the sheet movement via a finite element method. The experimental results had a satisfactory agreement with the calculated and simulated predictions, establishing the significance of this analysis method. The experimental validation carried out highlights the importance of the prediction of discharge current, the magnetic field, and the influence of a coupled workpiece on the distribution of electromagnetic force (and subsequent deformed profile of the workpiece).
ISSN:0924-0136
1873-4774
DOI:10.1016/j.jmatprotec.2018.08.033