Electromagnetic forming of aluminum circular tubes into square tubes: Experiment and numerical simulation

Yu, Haiping; Chen, Jie; Liu, Wei; Yin, Huazhe; Li, Chunfeng

doi:10.1016/j.jmapro.2017.12.019

Cited by 34 publications

(6 citation statements)

References 16 publications

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“…EMIF is a kind of powerful and high-speed forming technique where the deformation velocity can reach up to 300 m•s −1 [75] and the strain rate of the sheet metal is of the order of approximately 103•s −1 [76][77][78]. To precisely control the material behaviour in EMIF and obtain parts without defects, various techniques were employed, such as applying two-step forming [79], using tailored forming coils [80], selecting optimized process parameters [81], predicting formability and failure [82] and electromagnetic calibration [81,83]. EMIF is a powerful technique that can promote significant increases in the strain to failure in low ductility materials because of the strain rate and inertial effect [84].…”

Section: Electromagnetic Incremental Formingmentioning

confidence: 99%

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

Trzepieciński

Najm

Oleksik

et al. 2022

Metals

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Due to a favourable strength-to-density ratio, aluminium and its alloys are increasingly used in the automotive, aviation and space industries for the fabrication of skins and other structural elements. This article explores the opportunities for and limitations of using Single- and Two Point Incremental Sheet Forming techniques to form sheets from aluminium and its alloys. Incremental Sheet Forming (ISF) methods are designed to increase the efficiency of processing in low- and medium-batch production because (i) it does not require the production of a matrix and (ii) the forming time is much higher than in conventional methods of sheet metal forming. The tool in the form of a rotating mandrel gradually sinks into the sheet, thus leading to an increase in the degree of deformation of the material. This article provides an overview of the published results of research on the influence of the parameters of the ISF process (feed rate, tool rotational speed, step size), tool path strategy, friction conditions and process temperature on the formability and surface quality of the workpieces. This study summarises the latest development trends in experimental research on, and computer simulation using, the finite element method of ISF processes conducted in cold forming conditions and at elevated temperature. Possible directions for further research are also identified.

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Section: Electromagnetic Incremental Formingmentioning

confidence: 99%

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

Trzepieciński

Najm

Oleksik

et al. 2022

Metals

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“…The change of magnetic field and Lorentz force is calculated in the electromagnetic field module. Lorentz force can be obtained according to (7). And the change of magnetic field is calculated according to ( 19)- (21).…”

Section: Simulation Of Emhf a Simulation Model In Comsol Multiphysicsmentioning

confidence: 99%

“…Electromagnetic forming (EMF) is a fast, intelligent and environment-friendly manufacturing technology which has widely been applied in deforming tubular or sheet metal work pieces [1]- [7]. It is a non-contact forming process using Lorentz force caused by the large discharge current flowing through the forming coil.…”

Section: Introductionmentioning

confidence: 99%

Design and Experiments of Electromagnetic Heating Forming Technology

Zhang

Wang

et al. 2019

IEEE Access

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Electromagnetic forming (EMF) has been widely applied in industries. However, it's still hard to form thick or hard metal work pieces due to the limitation of its system power. Moreover, increasing the input voltage or capacitors may cause the problem of insulation, reduce the lifetime performance of devices, and lead to the cost increase and safety issue. Therefore, this paper proposes a novel technology named electromagnetic heating forming (EMHF), which combines EMF with electromagnetic induction heating (EIH) based on their similar working principles to make it easier to form the thick or hard metal work pieces. The EMHF can reduce the deformation resistance of work pieces by preheating treatment, and produce small discharge energy to deform work pieces. A 5kV/1.68kJ/135µ F EMHF system with a high-current pulse generator and a high-frequency heating source, which consists of an autonomous currentfed push-pull resonant inverter based on a zero voltage switching circuit and a resonant network, has been designed, built, and tested successfully. A finite element model coupling with the electromagnetic field, solid mechanics field, thermal field, and deformed geometry has also been built in COMSOL Multiphysics to analyze the EMHF process. Tube compression EMHF experiments of different input voltages, thicknesses, and temperatures have been carried out. The experimental and simulation results demonstrate that the EMHF can reduce the requirements of the deformation process by preheating treatment, which can't be done by EMF. Besides, the deformation can be controlled by the preheating temperature during the EMHF process. Therefore, the EMHF has great potential in industrial applications.INDEX TERMS Electromagnetic forming (EMF), electromagnetic induction heating (EIH), electromagnetic heating forming (EMHF) system, pulse generator, inverter.

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“…In terms of hollow products, this technique is predominantly used for tube bulging and compressing, and it induces only a small change in workpiece wall thickness [1,2]. Yu et al [3] investigated one-stage and two-stage forming of square tubes from circular tubes. The authors found that the one-stage process was characterized by the occurrence of underfill in the die cavity corners.…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Study on the Effect of Selected Parameters in a New Method of Extrusion with a Movable Sleeve

Winiarski

2022

Materials

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This paper presents a new method for forming hollow flanged products. The method involves extrusion with the use of a sleeve moving in the opposite direction to that of the punch. A tube with a constant hole diameter and two different outside diameters, made of aluminum alloy EN AW 6060 was used as a material. Numerical calculations were performed using Deform 2D/3D. Experiments were conducted on the PYE 160SS hydraulic press equipped with a specially designed device in which the punch is driven by the press slide while the moveable sleeve is driven by two hydraulic servomotors. Both numerical simulations and experiments were conducted under cold forming conditions. The aim of this study was to determine the effect of selected parameters (flange diameter, height of the cavity in the moveable sleeve, and the chamfer angle between the regions with different outside diameters on the workpiece and in the moveable sleeve cavity) on the stability of the extrusion process. Results were then used to undertake detailed comparative analyses of underfill, flange heights, and flange flank inclination angles. Findings of the analyses served as a basis for drawing conclusions regarding the effect of the analyzed parameters on the investigated extrusion process.

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Electromagnetic forming of aluminum circular tubes into square tubes: Experiment and numerical simulation

Cited by 34 publications

References 16 publications

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

Design and Experiments of Electromagnetic Heating Forming Technology

Theoretical and Experimental Study on the Effect of Selected Parameters in a New Method of Extrusion with a Movable Sleeve

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