Abstract
Improving the forming efficiency at a reasonable cost has been the main challenge in the electromagnetic forming technology. Towards this aim, this paper proposes a simultaneous cost-effective double-sheet electromagnetic forming method using single driving coil. In order to highlight the features of the proposed technique, comparison of the performance of five electromagnetic forming models is presented. These models include a no-sheet model, single-sheet stationary model, single-sheet moving model, double-sheet stationary model and double-sheet moving model. For each model, electromagnetic force distribution and forming efficiency of the workpiece are analyzed. Furthermore, the influence of the pulse current width of the driving coil on the electromagnetic forming efficiency of the plate is investigated for all models. Results show that for the same system discharge parameters, electromagnetic forming efficiency of double-sheet is 21.14% whereas the single-sheet electromagnetic forming model only achieves 14.68% efficiency. Thus, the double-sheet electromagnetic forming technology can improve the low forming efficiency of a single-sheet electromagnetic forming method and at the same time, the method can form two workpieces simultaneously which makes it more cost effective than the single-sheet method.
Highlights
Electromagnetic forming (EMF) is an industrial technology that uses high speed pulsed electromagnetic force to achieve a forming process for metal material [1]–[3]
When EMF is performed on two sheets the final speed of the sheets is 113m/s, kinetic energy of the two sheets is 1754.6J, and the forming efficiency is 17.1%. these results show that using double-sheet EMF improves the forming efficiency of the plate
This paper proposes a cost-effective technique to improve the EMF efficiency based on double-sheet model
Summary
Electromagnetic forming (EMF) is an industrial technology that uses high speed pulsed electromagnetic force to achieve a forming process for metal material [1]–[3]. A high intensity driving coil was presented in [16] to optimize the width of the pulse discharge current and improving the forming efficiency of a sheet electromagnetic bulging process. In order to further improve the efficiency of metal sheet EMF while maintaining the cost of the hardware setup, this paper presents a new EMF approach that utilizes a single driving coil to form two sheets at the same time This doublesheet EMF technology is investigated through building an electromagnetic-structure coupling model for the traditional sheet electromagnetic forming process that is validated experimentally. In the process of sheet EMF, the structure of the driving coil, workpiece and the source of the electromagnetic field is of spatial symmetry, which can simplify the entire system into a two-dimensional axisymmetric model In this model, the induced eddy current in the sheet is mainly dominated by the hoop component as described by the below equations. P and m are 6500s−1 and 0.25, respectively
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