Analysis of the Increased Formability of Aluminum Alloy Sheet Formed Using Electromagnetic Forming

Imbert, J.; Worswick, Michael J.; Winkler, S.; Golovashchenko, Sergey F.; Dmitriev, Victor

doi:10.4271/2005-01-0082

Cited by 33 publications

(20 citation statements)

References 18 publications

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“…Imbert et al (2005b) investigated EMF of AA5754 sheet into an open die (free-forming) and a conical die (112 • apex angle) and observed maximum strains on the order of ∼35-45% at high rates as compared to quasi-static strains of 20-30%. In another study, Imbert et al (2005a) measured maximum engineering strains of ∼65% for AA5754 formed by the EMF technique into a conical die (100 • apex angle) as compared to quasi-static strains of ∼20-30%. Oliveira and Worswick (2003) measured maximum engineering strains of ∼40-50% when forming AA5754 by EMF into a rectangular die.…”

Section: Introductionmentioning

confidence: 99%

Experimental characterization of sheet metal deformation during electro-hydraulic forming

Rohatgi

Stephens

Soulami

et al. 2011

Journal of Materials Processing Technology

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Section: Introductionmentioning

confidence: 99%

Experimental characterization of sheet metal deformation during electro-hydraulic forming

Rohatgi

Stephens

Soulami

et al. 2011

Journal of Materials Processing Technology

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“…For example, Imbert et al used a combination of the commercial codes ANSYS/EMAG and LS-DYNA, which are respectively used for electrical field analysis and structural simulation, to predict the behavior of EMF [6,7]. A link between the electromagnetic field analysis software and the mechanical field code has also been developed, by which finite element modeling of the EMF process was accomplished [8].…”

Section: Introductionmentioning

confidence: 99%

Two-step electromagnetic forming process using spiral forming coils to deform sheet metal in a middle-block die

Noh

Song

Kang

et al. 2014

Int J Adv Manuf Technol

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Two-step electromagnetic forming (EMF) of a metal sheet into the shape of a middle block is proposed in this paper. EMF is a high-speed forming process involving the application of a Lorentz force to the workpiece. The high speed of the forming process produces bouncing of the workpiece, which may result in poor shape accuracy owing to the absence of a medium between the coil and the workpiece. The proposed two-step EMF was used to solve this problem. In the demonstration of the proposed method, a 3D numerical simulation of the current supplied through the forming coil was performed using an LS-DYNA electromagnetism module, and the results were used to select a spiral forming coil with a 50-mm dead zone for the first step of deforming the workpiece. The process did not adequately achieve the desired shape, and, based on the results of another simulation, a second forming coil with a 20-mm dead zone was used for the second forming step of completing the fit with the forming die. The experimental results showed that the accuracy in shape achieved by the proposed multistep forming process was better than that of the single-step process, especially regarding the reduced wrinkling and sharpness of the edge of the workpiece.

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“…EMF is also known to increase the formability of some materials because of the absence of mechanical stress and friction encountered with mechanical forming processes. However, the basis for the increased formability in EMF is still a matter of discussion 64,65 .…”

Section: Electromagnetic Formingmentioning

confidence: 99%

Innovative forming and fabrication technologies : new opportunities.

Davis¹,

Hryn²

2008

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Executive SummaryThe state of technology in the field of fabrication and materials forming is reviewed. The purpose of this work is to identify new fields of Research & Development (R&D) that can lead to a significant reduction in energy consumption. This report, based on an extensive literature survey, identifies sheet aluminum alloy manufacturing, forming, and applications as a core aspect, but also highlights other types of sheet metal alloys and materials.This study found that aluminum alloy sheet manufacturing by the direct chill (DC) casting process is a mature technology where only marginal energy savings can be expected. Energy savings in this field can be accomplished mainly by individual plant wide assessments of energy consumption followed by optimization work. A possible breakthrough would come from advanced melting techniques such as plasma heating. As well, immersion heaters were recently identified as showing potential. An emerging technology in sheet manufacturing is spray rolling. The process could save 4.6x1012 kJ per year of energy for the U.S. aluminum industry. Even though the process has been proven to be technically feasible, the industrial implementation of spray rolling might need a significant effort. Improvements to the twin-roll casting process by coupling it with rheocasting could be an interesting method that would be easier to implement on the industrial scale.Extensive research has been performed to develop processes capable of forming commercial aluminum alloys for applications in the automotive industry. The following processes are considered advanced forming technologies: superplastic forming, electromagnetic forming, age forming, warm forming, and hydroforming. They are not necessarily new but can be regarded as emerging technologies with respect to their application to aluminum alloys. Superplastic forming is already being used industrially; however, simple and inexpensive manufacturing methods for the production of superplastic aluminum sheets still require further development. Any breakthrough in the forming of sheet materials will most likely come from the development of new alloys with very high formability at low temperature or the development of processing techniques to improve formability of existing alloys that will relax the stringent requirements of the forming techniques themselves. To have significant achievements in alloy development, thermodynamic models must be developed (or improved). The recent developments in quantum physics applied to aluminum alloys could pave the way for very efficient alloy development.Aluminum alloys are currently the material of choice to reduce weight in the automotive industry because of their commercial availability and the maturity of the aluminum industry. Opportunities still exist in the field of lightweight materials having high specific strength. Among those materials are magnesium alloys. Magnesium alloys could allow for further weight savings but high formability and high corrosion resistant alloys must be developed to overc...

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Analysis of the Increased Formability of Aluminum Alloy Sheet Formed Using Electromagnetic Forming

Cited by 33 publications

References 18 publications

Experimental characterization of sheet metal deformation during electro-hydraulic forming

Experimental characterization of sheet metal deformation during electro-hydraulic forming

Two-step electromagnetic forming process using spiral forming coils to deform sheet metal in a middle-block die

Innovative forming and fabrication technologies : new opportunities.

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