Pdf an analysis of electromagnetic sheet metal forming process. Electromagnetic forming emf is a non conventional metal working process that relies on the use of electromagnetic forces to deform metallic materials at high speeds. It is occasionally used to form flat sheet, and it is often used to combine several forming and assembly operations into a single step. The magnetic pulse and the extreme deformation speed transforms the metal into a viscoplastic state increasing formability without. Medraj mech 4216511 lecture 102 stretch forming sheet metal is stretched and simultaneously bent to achieve shape change 1 start of. In electromagnetic metal forming, there are no moving tools which push, press, or move the work piece material. If expansion is the goal, the solenoid workcoil is placed inside the closed metal shape, and thus expanded upon the current impulse. Intense electromagnetic pulses can be used to induce strong electric currents in electrically conductive work pieces. The ohio state university researchers, led by daehn and. This is a suitable method for forming metallic materials. In recent years, sheet metal forming shows tendencies to process a smaller number of parts per unit. Magnetic pulse technology mpt forming welding is a highspeed metal processing technology which uses electromagnetic force to form or weld various materials, and is especially good for aluminum and copper alloys that have a high electrical conductivity. More than 90% of smelted metal is processed by different methods of metal forming. Leone institute of fundamental electrical engineering and electromagnetic compatibility university of magdeburg, germany suitable simulation approaches for the preliminary investigation of the electromagnetic metal forming process are presented.
Pdf electromagnetic forming emf is a highspeed forming process that uses energy density of a pulsed magnetic field to deform metallic workpieces find, read and cite all the research you. Magnetic metal forming or welding induced heating resistive spot welding sliding contact for rail gun applications coupling with cfd solver for kettle applications battery crush in electric car crash. Further, in metal forming domain, few concepts of electromagnetic forming are invented, which are completely different from this clamping concept, 14. Thus, the average energy consumption is low in most applications, in the area of 2 to 3 kw. Abstract present day accelerator development requires new technologies for their diverse needs. Collision welding induced by metal vaporization the ohio state university osu has a portfolio of impulse based welding, shaping, joining and forming technologies which have been developed through cutting edge research over the last 20 years with the direction of dr. Advantages of electromagnetic metal forming low energy consumption. Electromagnetic forming concept 3d cad model library. Aluminum and ahss have limited formability at room temperature and conventional strain rates. Based on the use of innovative materials it is necessary to find the suitable forming technologies for specific material properties. Archived from the original pdf on 20051218 electromagnetic hemming machine and method for joining sheet metal layers. Electromagnetic forming a technique with potential. One of the most important application fields of electromagnetic forming is plastic metal forming. Issn 22295518 finite element analysis of electromagnetic.
Electromagnetic forming and joining for automotive. The electromagnetic forming emf process is a highdynamic process with high transformation velocities and was developed in the 1960s. Emf technology what is emf electromagnetic metal forming. Electromagnetic metal forming for advanced processing technologies. Fraunhofer institute for machine tools and forming technology iwu, chemnitz, germany, eu abstract. Simpler to use and less demanding than competing high speed metal forming processes that use explosives and shock waves, it is specially well suited for work with highly conductive metals like. A pinched aluminium can, produced from a pulsed magnetic field created by rapidly discharging 2 kilojoules from a high voltage capacitor bank into a 3 turn coil of heavy gauge wire.
Experimental study of electromagnetic sheet metal forming. Main electromagnetic metal forming for advanced processing technologies. These effects increment the value of the fields at the coilworkpiece interspace and they are more evident at higher frequencies. Finite element modeling and simulation of electromagnetic. Electromagnetic metal forming for advanced processing. Structuring by electromagnetic forming and by forming with an.
Apr 20, 2016 electrohydraulic forming and electromagnetic forming topics covered 1 introduction 2 process principle 3 constructional details 4 advantages and disadvanta slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Electromagnetic pulse forming is a promising direct method for a high speed sheet metal forming of materials with high conductivity, like al and cualloys. Comparative research on the rebound effect in direct. We take into account effects such as the skin and proximity effects see fig. It is an impulse or highvelocity forming method using pulsed magnetic field by application of lorentz forces to the work piece preferably made of highly electrically conductive material without having working medium and mechanical contact. Electromagnetic forming emf is a high speed metal forming method where materials with good electrical conductivity are formed by means of large magnetic pressures. Metal forming is the main method of making metal products and semifinished products. We have developed a 3d finite elements analysis toolbox for the simulation of electromagnetic forming emf within the frame of the software forge. Although very high electrical current is required to generate the high intensity electromagnetic field, the duration of the current is only approximately 50 to 100 micro seconds. Us patent and trademark office permanent dead link.
Plastic properties of metals are used during the process of metal forming. Electromagnetic forming concept 3d cad model library grabcad. The interaction of the electromagnetic field and the induced currents generate forces sufficiently large to form the work piece material beyond its yield point. A twodimensional 2d axisymmetric finite element model with the equations of electrical equivalent circuit, electromagnetic field, and mechanical field has been developed for calculating the discharge currents through the forming coil, the magnetic. It has a variety of applications in many industries, viz. That process is really good to stamp aluminum and any good metal. Nov 24, 2017 electromagnetic forming em forming or magneforming is a type of high velocity, cold forming process for electrically conductive metals, most commonly copper and aluminium. Erman tekkaya, iul, technical university, dortmund, germany 2. Electrohydraulic forming is a type of metal forming in which an electric arc discharge in liquid is used to convert electrical energy to mechanical energy and change the shape of the workpiece. The work piece is rapidly accelerated, reaching plasticity.
Conventional electromagnetic sheet metal forming approaches, aim at processing the complete. The forming force is created by the magnetic field acting on the work piece, so there is no need to use a traditional tool for forming, and it can be performed without any contact of the surface. Electromagnetic metal forming advance in the development of theoretical and numerical models of the emf process. The oscillation frequency of the discharge is a key parameter in the design of an emf system. Dynamic analysis of electromagnetic sheet metal forming. A productionoriented approach in electromagnetic forming of.
Electromagnetic forming em forming or magneforming is a type of high velocity, cold forming. Numerical simulation of electromagnetic forming process. He currently leads the impulse manufacturing laboratory at osu. Electromagnetic forming concept likes 3d cad model library. Electromagnetic location systems for metalnon metal mines. Mechanically, this is a highstrain rate forming process. This unit is a lab prototype, developed when i was studying for my master degree. The setup involves a capacitor bank that consists of maximum 8 capacitors, each having 5600f capacitance and can be charged up to. Explosive forming creates a more powerful shock wave by detonating high explosives within the fluid. Im sending this project with a lot of renderings and a pdf explaining in a simple way how electromagnetic fields deform metal.
Especially demands of modern lightweight design seem to be hard to satisfy by stretching conventional production methods. Electrohydraulic forming and electromagnetic forming topics covered 1 introduction 2 process principle 3 constructional details 4 advantages and disadvanta slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Therefore, hollow profiles can be compressed or expanded as well as 2d or 3d sheet metal can be shaped, joined or cut. Electromagnetic manufacturing process is the state of art technology for shaping and joining of metals based on electromagnetic forming and electromagnetic welding. Pdf an analysis of electromagnetic sheet metal forming. Electromagnetic forming emf is an impulse forming technology using pulsed magnetic field to apply lorentz forces to deform work pieces, which as one of the highspeed forming methods attracts increas ing scientific interests owing to the significant properties in improving the formability of sheet metal and reducing springback and wrinkling. In spisf, a sheet of metal is deformed by using numerically controlled singlepoint, hemispherical endshaped forming tool, which incrementally deforms. The process starts when a capacitor bank is discharged through a coil. Progress in blankholder systems in the pulsating blankholder system the blankholder is subjected to a vibratory pulsating force. The emf of aluminum alloy sheet metal can be divided into two categories. Electromagnetic forming emf is a high velocity forming technique that reshapes electrically conductive materials by abruptly discharging a bank of capacitors through a coil.
The force or electromagnetic pressure pulse generally 50 to 100 microseconds long imparts kinetic energy into the work piece. Lightweight design electromagnetic forming elastomer tool structure stiffness acoustic. Depending upon the coil configuration, various stamping processes can be carried out, such as tube expansion, tube compression, and flat sheet forming 1. Electromagnetic forming emf is a high velocity forming technique that uses. Sheet metal fabrication ranges from deep drawing, stamping, forming, and hydro forming, to highenergyrate forming. Hello fellow wikipedians, i have just modified 4 external links on electromagnetic forming. A numerical model for the search of the optimum frequency in. Electromagnetic forming emf is a noncontact forming technique.
For comparative study, a conventional fixture is also designed and fabricated. This book focuses on the new direction of magnetic pulsed metal working by attraction of sheet metals. Adapting electromagnetic forming technology for the automotive industry. Electromagnetic forming process emf is advanced high velocity metal forming process which deals with the application of high energy. High strain rate forming ppf can enhance room temperature formability. A typical application area is the electromagnetic tube compression. A novel electromagnetic fixture for incremental sheet. Singlepoint incremental sheet forming spisf is a promising dieless forming technique. Electromagnetic pulse forming of carbon steel sheet metal. Sheet metal is used in the production of materials ranging from tools, to hinges, automobiles etc. Sheet metal fabrication plays an important role in the metal manufacturing world. The workpiece is reshaped by high intensity pulsed magnetic fields that induce a current in the workpiece and a corresponding repulsive magnetic field, rapidly repelling.
Electromagnetic forming and joining for automotive applications. It is a very fast process where materials can achieve strain rates higher than 103 s. In this study, experimentation on an electromagnetic forming emf setup for bulging of flat metal sheets is presented. Electromagnetic forming, finite elements, image analysis.
Design and fabrication of electromagnetic fixture for. Flat forming electromagnetic forming emf is a high velocity forming process using the energy density of a pulsed magnetic field to form or to accelerate workpieces of good electrical conductivity. Powder metal forming parts sintered metal parts metal injection moulding parts net shape metal power parts suranaree university of technology september 2007 introduction to metal forming metal sheet forming products t. Numerical simulation of electromagnetic forming process using. Simulation models of the electromagnetic forming process. The differences in the results can be attributed to the different features of each model. Performance analysis of electromagnetic forming process grin. Experimental study of electromagnetic sheet metal forming process. Incontrast to the more conventional electromagnetic forming variants, this processisnotlimitedtoworkpiecesmadeofanelectricallyconductive material.
Electromagnetic metal forming for advanced processing technologies yuriy batygin, marina barbashova, oleh sabokar auth. Forming, joining, tooling, springback 1 introduction in pulsed electromagnetic forming and joining a coil can be described as a tooling replacing a punch in conventional forming operations. This paper presents a simple and efficient method for the analysis of dynamic behavior of the workpiece in the electromagnetic forming process. Simulation models of the electromagnetic forming process g. He is one of the founding members and chair of the international impulse forming group. This process is primarily used for three forming operations, namely, sheet metal forming, tube expansion, and tube compression. From the modeling and simulation perspective, it can be identified as a coupled multyphysics problem, involving circuits, electromagnetic fields and structural deformations. A capacitor bank delivers a pulse of high current across two electrodes, which are positioned a short distance apart while submerged in a fluid water or oil. That process is really good to stamp aluminum and any good metal conductor. Electromagnetic pulse forming of carbon steel sheet metal r.
The workpiece is reshaped by high intensity pulsed magnetic fields that induce a current in the workpiece and a corresponding repulsive magnetic field, rapidly repelling portions of the workpiece. Electromagnetic forming em forming or magneforming is a type of high velocity, cold forming process for electrically conductive metals, most commonly copper and aluminium. Pdf electromagnetic forming emf is a highspeed forming process that uses energy density of a pulsed magnetic field to deform metallic. Pulsed electromagnetic forming also finds applications in joining and cutting. Electromagnetic forming and joining for automotive applications s. Jun 30, 2014 this video depicts the new electromagnetic forming method called the openable actuator. Electromagnetic forming emf is a high velocity forming technique that uses electromagnetic forces to shape metallic workpieces. A numerical model for the search of the optimum frequency. Elsebaie abstract electromagnetic forming is a high velocity forming technique that uses high pulsed current to produce repulsion electromagnetic pressure between a forming coil and the workpiece.
We used a more realistic electromagnetic model for the coil than zhang et al. Electromagnetic forming is chiefly used to expand, compress, or form tubular shapes. Stretch forming automotive stamping processes stretch forming vs. Pdf by exploiting the potential advantages of electromagnetic forming, a comprehensive approach has been developed for large sheet metal. Finite element analysis of electromagnetic bulging of sheet metals ali m.
Electromagnetic forming is an impulse or highspeed forming technology using pulsed magnetic field to apply lorentz forces to workpieces preferably made of a highly electrically conductive. Magnetic pulse welding and forming are unique high speed. Electromagnetic forming machine type ife10 technical characteristics. Electromagnetic forming emf is a highspeed forming technology that can be applied for shaping as well as as for joining and cutting of sheet metal and profileshaped workpieces made of electrically conductive materials. Pdf a comprehensive electromagnetic forming approach for large. Process types resulting of the coilworkpiece arrangement c l i r i emf is used for joining, forming, and cutting of thinwalled tubes. Iii electromagnetic forming the electrical energy stored in a capacitor bank is used to produce opposing magnetic fields around a tubular work piece, surrounded by current carrying coils. Pulsed electromagnetic forming pulsed electromagnetic forming process is a high speed metal forming that deforms sheets of metal in less than 1 ms time. The basic principle for creating the simulation models is illustrated in figure 1.
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