Electromagnetic forming of aluminum alloy sheet: Free-form and cavity fill experiments and model

Oliveira, D. A.; Worswick, Michael J.; Finn, M.; Newman, D.C.

doi:10.1016/j.jmatprotec.2005.04.118

Cited by 191 publications

(59 citation statements)

References 20 publications

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“…The durability of coil systems and methods for the economical design, construction, and implementation still need to be demonstrated. Other recent university research has confirmed that EMF is a viable process for aluminum sheet forming 67 .…”

Section: Electromagnetic Formingmentioning

confidence: 90%

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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Section: Electromagnetic Formingmentioning

confidence: 90%

Innovative forming and fabrication technologies : new opportunities.

Davis¹,

Hryn²

2008

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“…In such case top metal layer undergoes a deformation that leads to its structure disruption [3][4][5]. Magnetic-pulse straightening methods are devoid of these drawbacks because the interaction of the magnetic field with the induced current (fullthickness of processed metal) initiates a metal stretching by attraction forces that act throughout its full-thickness [1,2,[6][7][8][9].…”

Section: Publications Analysismentioning

confidence: 99%

New Method of Car Body Panel External Straightening: Tools of Method

Гнатов

Argun

2015

International Journal of Vehicular Technology

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Recently repair and recovery vehicle body operations become more and more popular. A special place here is taken by equipment that provides performance of given repair operations. The most interesting things are methods for recovery of car body panels that allow the straightening without disassembling of car body panels and damaging of existing protective coating. Now, there are several technologies for repair and recovery of car body panels without their disassembly and dismantling. The most perspective is magnetic-pulse technology of external noncontact straightening. Basics of magnetic-pulse attraction, both ferromagnetic and nonferromagnetic thin-walled sheet metal, are explored. Inductor system calculation models of magnetic-pulse straightening tools are presented. Final analytical expressions for excited efforts calculation in the tools under consideration are introduced. According to the obtained analytical expressions, numerical evaluations of excited forces were executed. The volumetric epures of the attractive force radial distributions for different types of inductors were built. The practical testing of magnetic-pulse straightening with research tools is given. Using the results of the calculations we can create effective tools for an external magnetic-pulse straightening of car body panels.

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“…Introduction Oliveira et al (2005) explained thatSheet metal forming processes often involve high rates of deformation. Electromagnetic pulse forming (magnetic pulse forming),hydro forming and explosive forming are obvious examples, but also in more conventional sheet forming techniques, such as deep drawing, roll forming and bending, locally high strain rates occur deviating from those used in static material tests.…”

Section: Imentioning

confidence: 99%