Analyzing the electromagnetic forming process of SS304 sheet using AA6061-T6 driver through a fully coupled numerical model and experimentally validation

Abstract

Abstract. Driver-based electromagnetic forming (EMF) is a process that uses electromagnetic forces to form metal components into a desired shape. The process involves the use of a conducting driver metal, which is driven by an electromagnetic coil that generates a high-frequency, high-amplitude current. The driver sheet pushes the nonmagnetic sheet metal workpiece against a die causing it to be deformed into the desired shapes. EMF is particularly useful for forming complex shapes and for creating precise forms with minimal material loss. Applications of EMF include the formation of aerospace and automotive components, medical devices, and other products that require precise shaping and minimal material waste. This research focuses on the driver-based electromagnetic forming of Austenitic Stainless Steel (SS304) sheets using Aluminum alloy (AA6061-T6) as a driver. The analysis includes the numerical results of the magnetic field, Lorentz force, sheet deformation and velocity at four points on the sheet profile. The study also compares the numerical results to experimental measurements of the sheet profile. The study found that the numerical results were in good agreement with the experimental results.