High-speed forming processes such as electromagnetic forming (EMF) and electrohydraulic forming (EHF) have a high potential for producing lightweight components with complex geometries, but the forming zone is usually limited to a small size for equipment-related reasons. Incremental strategies overcome this limit by using a sequence of local deformations to form larger component areas gradually. Hence, the technological potential of high-speed forming can be exploited for large-area components too. The target-oriented process design of such incremental forming operations requires a deep understanding of the underlying electromagnetic and electrohydraulic forming processes. This article therefore analyzes and compares the influence of fundamental process parameters on the acting loads, the resulting course of deformation, and the forming result for both technologies via experimental and numerical investigations. Specifically, it is shown that for the EHF process considered, the electrode distance and the discharge energy have a significant influence on the resulting forming depth. In the EHF process, the largest forming depth is achieved directly below the electrodes, while the pressure distribution in the EMF depends on the fieldshaper used. The energy requirement for the EHF process is comparatively low, while significantly higher forming speeds are achieved with the EMF process.
The control of workpiece properties enables an application-oriented and time-efficient production of components. In reverse flow forming, e.g., the control of the microstructure profile, in contrast to the adjustment of the geometry, is not yet part of the state of the art. This is particularly challenging when forming seamless tubes made of metastable austenitic stainless AISI 304L steel. In this steel, a phase transformation from austenite to martensite can occur due to mechanically and/or thermally induced energy. The α’-martensite has different mechanical and micromagnetic properties, which can be advantageous depending on the application. For the purpose of local property control, the resulting α’-martensite content should be measured and controlled online during the forming process. In this paper, results from an empirical correlation model of process parameter combinations and resulting α’-martensite content as well as geometry will be presented. Based on this, the focus of the paper will be on process modeling by means of FEM in order to create the transition to a numerically supported process model. Furthermore, it will be specified how the numerical process model can be used in a predictive manner for an online closed-loop process control.
The adaptive joining process employing friction-spun joint connectors (FSJC) is a promising method for the realization of adaptable joints and thus for lightweight construction. In addition to experimental investigations, numerical studies are indispensable tools for its development. Therefore, this paper includes an analysis of boundary conditions for the spatial discretization and mesh modeling techniques, the material modeling, the contact and friction modeling, and the thermal boundary conditions for the finite element (FE) modeling of this joining process. For these investigations, two FE models corresponding to the two process steps were set up and compared with the two related processes of friction stir welding and friction drilling. Regarding the spatial discretization, the Lagrangian approach is not sufficient to represent the deformation that occurs. The Johnson-Cook model is well suited as a material model. The modeling of the contact detection and friction are important research subjects. Coulomb’s law of friction is not adequate to account for the complex friction phenomena of the adaptive joining process. The thermal boundary conditions play a decisive role in heat generation and thus in the material flow of the process. It is advisable to use temperature-dependent parameters and to investigate in detail the influence of radiation in the entire process.
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