Analytical Modeling and Optimization Design of an Electromagnetic Pulse Welding Device With a Field Shaper for Metal Plates

Hang Zhang,Qingjian Wang,Guangda Wang,Hongfa Ding

doi:10.1109/access.2020.3030909

Abstract

An electromagnetic pulse welding (EMPW) system is a complex multifield coupling system. Using finite element software to simulate its processes can better guide the design of the electromagnetic pulse welding system and the analysis of the welding mechanism. However, the existing finite element software has a complex model, involves a large amount of calculation, and is time consuming, which is not conducive to the optimization of the welding device. In this paper, an equivalent circuit model based on an improved current wire method is proposed, and the welding process is modeled and analyzed, and then compared with the simulation results of the finite element software COMSOL. The results show that the analytical model is accurate and effective, and it can reduce the calculation time and improve the processing efficiency. Second, based on the equivalent circuit model and taking the maximum impulse of the electromagnetic force as the optimization objective, the shape parameters of the field shaper and the number of turns of the coil in the electromagnetic welding device for plates based on the field shaper are optimized, and the optimal parameters are obtained. Finally, the welding equipment is designed with the optimal parameters, and the electromagnetic welding platform is built. An SS304 stainless steel plate and A1060 aluminum plate with a thickness of 1 mm are welded, and the dissimilar metal plates are well connected.

Highlights

With the development of the economy and of technology, vehicles are becoming increasing diversified
From the analysis of the macroscopic plastic deformation process, it can be seen that in the electromagnetic pulse welding based on the field shaper, the aluminum plate with better conductivity undergoes severe plastic deformation, and the deformation position just corresponds to the distribution of electromagnetic force analyzed above, while the stainless steel plate, with poor conductivity, shows almost no deformation
In this paper, the equivalent circuit model of an electromagnetic pulse welding device is established to solve the problem of electromagnetic coupling between the components

Summary

INTRODUCTION

With the development of the economy and of technology, vehicles are becoming increasing diversified. Kore et al [12]–[14] used ANSYS to simulate the electromagnetic field in the welding process, calculated the electromagnetic force at different times for the workpiece node, and imported it into ABAQUS to simulate the welding collision process, achieving the loose coupling of the electromagnetic field and structural field. The input of the simulation is the measured current curve or the current curve obtained by other software simulations, so a coupling analysis of the electromagnetic welding and discharge circuit is rarely found [18]; the model is complex, and the calculation is large and time consuming. By coupling the discharge circuit to the electromagnetic pulse welding process, the calculation accuracy can be improved. The welding device is optimized and the welding experiment is carried out

ESTABLISHMENT OF AN EQUIVALENT CIRCUIT MODEL

PARAMETERS OF THE EQUIVALENT MODEL

OPTIMIZATION OF WELDING EQUIPMENT

ANALYSIS OF THE PLASTIC DEFORMATION PROCESS OF THE PLATE

EXPERIMENT AND DISCUSSION

CONCLUSION