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A study of the effect of tool–sheet interaction on damage evolution in electromagnetic forming is presented. Free form and conical die experiments were carried out on 1 mm AA5754 sheet. Safe strains beyond the conventional forming limit diagram (FLD) were observed in a narrow region in the free form experiments, and over a significant region of the part in the conical die experiments. A parametric numerical study was undertaken, that showed that tool–sheet interaction had a significant effect on damage evolution. Metallographic analysis was carried out to quantify damage in the parts and to confirm the numerical results.

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