Abstract
Focus of present work is to develop a setup for high strain rate electromagnetic forming of thin aluminum sheets (0.5, 1.0, 1.5 and 2.0 mm) and optimization of forming parameters. Flat spiral coil of 99.9% pure Cu strip (2.5x8.0 mm) with self-inductance 11 μH, 13 no. of turns and resultant outer diameter of 130mm has been fabricated and was coupled to a capacitor bank of energy, voltage and capacitance of 9 kJ, 900 V and 22.8 mF, respectively. To optimize the coil design, a commercially available software FEMM-4.2 was used to simulate the electromagnetic field profile generated by the coils of different pitch but same number of turns. Results of electromagnetic field intensity proposed by simulation agree in close proximity with those of theoretical as well as experimental data. The calculation of electromagnetic force and magnetic couplings between the coil and metal sheet are made. Forming parameters were optimized for different sheet thicknesses. Electromagnetic field intensity's profile plays a principal role in forming of typical shapes and patterns in sheets.
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