Experimental Analysis of Interference-Fit Joining of Aluminum Tubes by Electromagnetic Forming

Geier, Martin; Paese, Evandro; Rossi, Rodrigo; Rosa, P.A.R.; Homrich, Roberto Petry

doi:10.1109/tasc.2020.2972499

Cited by 15 publications

(5 citation statements)

References 20 publications

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“…Electromagnetic forming is a non-contact high-speed pulse forming technology that can provide improved the forming limit of materials than traditional machining [1][2][3][4][5][6]. Based on the nature of the object, the electromagnetic forming is categorized into tube or sheet processing [7][8][9]. Much attention was given in the literature to improve the uniformity of tube electromagnetic bulging.…”

Section: Introductionmentioning

confidence: 99%

Simulation Analysis of the Electromagnetic Force Distribution and Formability Parameters for Sheet Metal Electromagnetic Bulging Using a New Magnetic Field Shaper

Qiu

Abu-Siada

et al. 2021

IEEE Access

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While electromagnetic forming of aluminum alloy sheet has gained several advantages, the uneven radial deformation of the sheet is still one of the main drawback of this technology that calls for reliable and cost-effective solution. Aiming at this point, this paper presents an electromagnetic bulging system equipped with a new magnetic field shaper placed between the driving coil and the object sheet to modulate the distribution of the induced eddy current in the sheet, and hence regulating the distribution of the electromagnetic force to achieve more uniform deformation. A finite element electromagnetic-structure 2D coupling model simulating this process is developed and the effects of workpiece geometry and deformation speed on the circuit, magnetic field and structure field are considered. The coupling between the electric circuit and magnetic field; magnetic field and workpiece deformation is realized to simulate the actual system of thin plate electromagnetic bulging. The performance of the proposed system is compared with that of the traditional system through investigating the profiles of the induced eddy current, electromagnetic force and forming effect. Simulation results show that the uniformity of sheet metal forming is improved by using the proposed magnetic field shaper, and the maximum uniform deformation area is increasing from 32.1mm to 73.8mm, which stimulates more industrial applications of sheet metal electromagnetic forming.

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Section: Introductionmentioning

confidence: 99%

Simulation Analysis of the Electromagnetic Force Distribution and Formability Parameters for Sheet Metal Electromagnetic Bulging Using a New Magnetic Field Shaper

Qiu

Abu-Siada

et al. 2021

IEEE Access

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show abstract

“…According to the type of the workpiece, the electromagnetic forming can be divided into sheet and tube electromagnetic forming. On the other hand, based on the loading method of the electromagnetic force, the tube electromagnetic forming is divided into electromagnetic expansion and compression [11][12]. In tube electromagnetic forming, the workpiece deformation uniformity and the wall thickness thinning have been considered the main issues that attracted many research attempts in the literature.…”

Section: Introductionmentioning

confidence: 99%

Parametric Simulation Analysis of the Electromagnetic Force Distribution and Formability of Tube Electromagnetic Bulging Based on Auxiliary Coil

et al. 2020

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Tube electromagnetic bulging has been given much attention due to its superior advantages in the field of light alloy processing. However, the conventional tube electromagnetic bulging process exhibits some critical issues that restrict its wide industrial applications. This includes non-uniform axial deformation and poor forming performance such as wall thickness thinning. This paper proposes a costeffective solution for such issues through simultaneous radial and axial electromagnetic force loading using an auxiliary driving coil. In this regard, the influence of the auxiliary coil geometrical parameters on the electromagnetic force distribution and tube forming performance is investigated using electromagneticstructure coupling model of the bulging process. The robustness of the new proposed method is validated by comparing its electromagnetic force distribution and tube forming performance with the traditional cylindrical coil method, currently used by industry practice. Numerical results show that the introduction of the auxiliary coil may effectively weaken the radial electromagnetic force at the end of the tube and solve the uneven axial deformation issue. Based on the obtained results, the maximum uniform deformation area is increased from 6.9mm to 35.1mm. The tube relative wall thinning issue is reduced and the relative wall thickness reduction of the pipe is found to be 0.01661. The axial electromagnetic force can be further improved by adjusting the geometrical parameters of the coil and the proposed electromagnetic bulging can effectively increase the uniform deformation range of the tube.

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“…Compared with conventional mechanical-based processing, EMF can improve plastic deformation ability of materials and enhance their forming limit about 5 to 10 times due to its high strain rate (10 3 -10 5 s -1 ) [4][5][6]. Because the electromagnetic force is of a non-contact nature [7,8], EMF is able to improve the surface quality of the formed workpiece [9][10][11].…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of Tube Expansion by Electromagnetic Forming Using Magnetic Field Shaper

et al. 2020

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Uneven axial deformation is the current main issue of the tubes electromagnetic bulging technology which calls for innovative and cost-effective solutions. This paper presents a new method to overcome the above-mentioned issue based on employing a magnetic field shaper. The proposed magnetic field shaper is employed in the middle of the pipe and the driving coil. Induced eddy current control is realized by changing the structural parameters of the magnetic field shaper; thereby regulating the electromagnetic force distribution. The effectiveness of the proposed method is investigated through numerically comparing the electromagnetic performance of two EMF setups; traditional coil-based loading model and magnetic field shaper driving coil-based loading model proposed in this paper. The influence of the magnetic field shaper structural parameters on the tube electromagnetic forming performance is examined for optimum structure design. Results reveal that the concave profile of the radial electromagnetic force in the traditional loading method can be effectively improved using the proposed loading in this paper. The introduction of a magnetic field shaper not only changes the induced eddy current distribution, but also regulates the electromagnetic force profile in the axial-direction of the pipe which effectively enhances the uniform range of the pipe electromagnetic bulging, the maximum uniform deformation area is increased from 9mm to 35mm.

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Experimental Analysis of Interference-Fit Joining of Aluminum Tubes by Electromagnetic Forming

Cited by 15 publications

References 20 publications

Simulation Analysis of the Electromagnetic Force Distribution and Formability Parameters for Sheet Metal Electromagnetic Bulging Using a New Magnetic Field Shaper

Simulation Analysis of the Electromagnetic Force Distribution and Formability Parameters for Sheet Metal Electromagnetic Bulging Using a New Magnetic Field Shaper

Parametric Simulation Analysis of the Electromagnetic Force Distribution and Formability of Tube Electromagnetic Bulging Based on Auxiliary Coil

Numerical Analysis of Tube Expansion by Electromagnetic Forming Using Magnetic Field Shaper

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