Abstract
Electromagnetic powder compaction is considered a high strain and high-speed powder forming technique. The method uses the Lorentz forces for compacting powder to obtain near net shape and high strength compact through the PM route. This process can be classified as a contactless powder compaction technique since no physical punch is used to form powder for compaction. All kinds of materials, irrespective of the powder particle's hardness and size distribution, can be compacted using this technique. Few materials are tough to compact due to their higher hardness as well the frictional forces are very high during the compaction of Nanosized metallic powder. These barriers can be easily overcome by using high velocity and energy, such as the electromagnetic forming technique. In this paper, a non-coupled finite element model is developed to simulate the electromagnetic powder compaction process of pure Aluminium. ANSYS-Maxwell is used to investigate the electromagnetic field distribution in electromagnetic powder compaction tooling setup. The Geologic Cap model was used in the LS-Dyna Multi-physics solver to describe powder deformation during the compaction process. The Johnson-Cook plasticity model describes the deformation behaviour of the Al 6063 packing tube. Finally, the developed simulation model is validated with experimental results of aluminium powder compacts at 12 kV and 13 kV. The powder compaction experiments were carried out using a 40 kJ capacity electromagnetic forming machine. It found that the simulation results agreed with experimental data results. The comparison is made between the final diameters of the compact obtained through simulation and experiments.
Published Version
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