A Numerical Model for the Search of the Optimum Frequency in Electromagnetic Metal Forming (original) (raw)
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A Frequency Domain Approach for Computing the Lorentz Force in Electromagnetic Metal Forming
International Journal of Applied Electromagnetics and Mechanics, 2014
In this paper we present a finite element model in frequency domain which computes the Lorentz force that drives an electromagnetic forming (EMF) process. The only input data required are the electrical parameters of the capacitor bank, the coil and the work piece. The main advantage of this approach is that it provides an explicit relation between the parameters of the EMF process and the frequency of the discharge, which is a key parameter in the design of an optimum EMF system. The method is computationally efficient because it only requires to solve time-harmonic Maxwell's equations for a few frequencies and it can be very useful for coil design and for testing modeling conditions on complex three-dimensional geometries.
Finite Element Analysis and Parametric Study of Electromagnetic Forming Process
International journal of engineering research and technology, 2014
The desire to produce light weight structures has stimulated the automotive and aerospace industry to direct their attention towards employing light weight, high strength to weight ratio material such as aluminium alloys. This has developed interest in understanding electromagnetic forming (EMF), which produces high strain rate using induced electromagnetic fields, thus enhancing the formability of aluminium alloys and reducing its wrinkling and spring-back. To get a better insight of the behavior and physics of EMF process a numerical model is highly necessary which helps to reduce the cost and time of the analysis. In this study, a three dimensional numerical simulation of tube compression process has been carried out on aluminium alloy AA3003 using commercially available finite element tool, Abaqus ®. Loosely coupled approach has been used in which the effect of tube deformation on electromagnetic field has been neglected. The final tube deformation is validated with experimental results. It was seen that there is a good correlation between the numerical simulation and the experimental results. The primary emphasis was made to determine the effect of discharge current frequency and discharge energy on final tube deformation and hence to find the optimum range of discharge current frequency and energy level of the system. The optimum discharge current frequency range was determined at different discharge energy levels. This study could serve as a valuable piece of information for better design of the EMF process by controlling the process parameters.
IJERT-Finite Element Analysis and Parametric Study of Electromagnetic Forming Process
International Journal of Engineering Research and Technology (IJERT), 2014
https://www.ijert.org/finite-element-analysis-and-parametric-study-of-electromagnetic-forming-process https://www.ijert.org/research/finite-element-analysis-and-parametric-study-of-electromagnetic-forming-process-IJERTV3IS120382.pdf The desire to produce light weight structures has stimulated the automotive and aerospace industry to direct their attention towards employing light weight, high strength to weight ratio material such as aluminium alloys. This has developed interest in understanding electromagnetic forming (EMF), which produces high strain rate using induced electromagnetic fields, thus enhancing the formability of aluminium alloys and reducing its wrinkling and spring-back. To get a better insight of the behavior and physics of EMF process a numerical model is highly necessary which helps to reduce the cost and time of the analysis. In this study, a three dimensional numerical simulation of tube compression process has been carried out on aluminium alloy AA3003 using commercially available finite element tool, Abaqus ®. Loosely coupled approach has been used in which the effect of tube deformation on electromagnetic field has been neglected. The final tube deformation is validated with experimental results. It was seen that there is a good correlation between the numerical simulation and the experimental results. The primary emphasis was made to determine the effect of discharge current frequency and discharge energy on final tube deformation and hence to find the optimum range of discharge current frequency and energy level of the system. The optimum discharge current frequency range was determined at different discharge energy levels. This study could serve as a valuable piece of information for better design of the EMF process by controlling the process parameters.
Effect of Coil Design on Tube Deformation in Electromagnetic Forming
2020
Research Scholar, Department of Mechanical Engineering, Maulana Azad National Institute of Technology, Bhopal, Madhya Pradesh, India Assistant Professor, Department of Mechanical Engineering, Maulana Azad National Institute of Technology, Bhopal, Madhya Pradesh, India Scientist, Materials & Processing Design Group, Advanced Materials and Processes Research Institute (AMPRI), Bhopal, Madhya Pradesh, India ABSTRACT
Mecanique et Industries, 2008
In the electromagnetic forming process (EMF, also known as magnetic pulse forming) the metal is deformed by applying a pressure generated by an intense, transient magnetic field. A great deal of research and investigation efforts are needed for gaining better understanding on the deformation mechanism in order to develop a suitable forming strategy and equipment. One way to reach this target is to employ suitable FE software to model the process. This investigation was partly conducted in the framework of a European project called EMF (G3RD- CT-2002-00798).
3D finite element modeling of electromagnetic forming processes
2006
In the electromagnetic forming process (EMF, also known as magnetic pulse forming) the metal is deformed by applying a pressure generated by an intense, transient magnetic field. A great deal of research and investigation efforts are needed for gaining better understanding on the deformation mechanism in order to develop a suitable forming strategy and equipment. One way to reach this target is to employ suitable FE software to model the process. This investigation was partly conducted in the framework of a European project called EMF (G3RD- CT-2002-00798).
Design and Testing of Coils for Pulsed Electromagnetic Forming
2006
Coil design influences the distribution of electromagnetic forces applied to both the blank and the coil. The required energy of the process is usually defined by deformation of the blank. However, the discharge also results in a significant amount of heat being generated and accumulating in the coil. Therefore, EMF process design involves working with three different problems: 1) propagation of an electromagnetic field through the coil-blank system and generation of pulsed electromagnetic pressure in specified areas, 2) high-rate deformation of the blank, and 3) heat accumulation and transfer through the coil with the cooling system. In the current work, propagation of an electromagnetic field in the coil, blank, die and surrounding air was defined using a consistent set of quasi stationary Maxwell equations applying a corresponding set of parameters for each media. Furthermore, a deformation of the blank driven by electromagnetic forces distributed through the volume of the blank ...
International Journal of Material Forming, 2009
Electromagnetic forming (EMF) is a non conventional metal working process that relies on the use of electromagnetic forces to deform metallic workpieces at high speeds. This study is divided out into three parts. The first part presents a method for calculating the process parameters; namely the electromagnetic problem. An in-house code written in FORTRAN is developed for the electromagnetic tube expansion. In the second part, the results obtained from the in-house code are compared with those obtained from the free finite element magnetic software FEMM. In addition to this verification, the results of the in-house code are compared with the experimental ones available in the literature. The in-house code is then introduced in the finite element commercial code ABAQUS/ Explicit. The third part presents the simulation of the electromagnetic tube bulging forming process for metal tubes using ABAQUS/Explicit with an axi-symmetric model. The simulations have been carried out for Al 1050 aluminium tubes of 1.0mm thickness. This part also provides the comparison between the numerical simulations and the available experimental studies in the literature. Finite element simulations of the tube expansion predicted the experimental trends.
A numerical model to simulate electromagnetic sheet metal forming process
International Journal of Material Forming, 2008
The objective of the present work is to build an efficient computational method for numerical simulation and to understand the dynamics of deformation during the electromagnetic forming process (EMF). The finite difference method is used to solve the electromagnetic problem. The magnetic pressure due to the body forces generated by electromagnetic induction is calculated. To verify the results obtained through the finite difference programme, the electromagnetic finite element code FEMM4.0 is used. An axisymmetric finite element model for electromagnetic free bulging process is developed with the commercial finite element code ABAQUS/Explicit. The magnetic pressure calculated is applied as a loading condition via a user subroutine VDLOAD to model the high rate deformation of the work piece. Results concerning magnetic fields and plastic deformation of the work piece are presented. A good agreement is found between the numerical results from finite difference method and FEMM4.0. The finite element predictions are also in agreement with the experimental results.
Modeling of the electromagnetic forming of sheet metals: state-of-the-art and future needs
Journal of Materials Processing Technology, 2003
The electromagnetic forming (EMF) process relies on a driving force that is induced by eddy current and magnetic field, both of which are generated in the workpiece by a transient current in a nearby coil. The high deformation rates achievable using this forming method enhances the formability of materials such as aluminum. Also, the dynamics of contact with the forming die can eliminate springback, an undesired effect that can be problematic in other forming techniques such as stamping. The advancement of the EMF technology is currently awaiting rigorous numerical modeling capabilities that can adequately simulate the forming process and be used to design the forming system. Such capabilities must be based on physical models that address the strong coupling between the electromagnetic, deformation and thermal response of the deforming workpiece and other system structure. In this paper, a brief exposition of the EMF method and its applications and a review of the existing models are given. In addition, a mathematical framework, which can be further developed numerically for the purpose of process simulation, is outlined. Finally, the paper discusses the challenges to advancing the EMF technology.