Integration of Electromagnetic Calibration into the Deep Drawing Process of an Industrial Demonstrator Part

Abstract

In recent years a steadily growing interest in applying lightweight construction concepts could be observed. This development is accompanied by an increasing demand for innovative forming strategies suitable for extending the forming limits of the typical lightweight materials. Deep drawing combined with an integrated electromagnetic calibration step is an example of such a technology. The feasibility and potential of this process combination is analyzed on the basis of a demonstrator part from the automotive industry. Thereby, aspects related to the practicability of the electromagnetic forming process itself are regarded as well as points related to the deep drawn preform. The concept of a 3D-coil insert, integrated into a deep drawing punch in order to realize the calibration in the deep drawing process, is introduced and based on the experimental results, conclusions regarding the applicability of the process combination are drawn.

Electromagnetic forming—A review

“…This idea is partly resumed in Psyk et al (2007). Here, the energy transfer is regarded, focusing on its effect on the forming result.…”

Production of low-volume aviation components using disposable electromagnetic actuators

“…4(a) and (b) shows an example of a traditional EMF tool which was embedded in a deep drawing punch. Psyk et al (2007) used this tool to investigate the feasibility and potential of a process combination of quasi-static preforming with a subsequent electromagnetic calibration step. In Fig.…”

“…4.0 kJ was chosen as the charging energy and 2000 lb was again selected as the press force. Psyk et al (2007) showed that, for electromagnetic forming, the charging energy stored in the capacitor bank is transformed first into a pressure pulse and then into kinetic and deformation energy. At the moment the workpiece hits the die the remaining kinetic energy is transferred from the workpiece into the die.…”

“…In this work, novel electromagnetic actuators are used that apply large local forces to the workpiece, permitting it to remain in the T6 temper condition throughout the entire forming process. Promising results of this combination of quasi-static and impulse forming have already been demonstrated by Vohnout (1998) and Psyk et al (2007). In both research works electromagnetic forming (EMF) was used to further form and calibrate aluminum sheet metal parts that were preformed by conventional deep drawing.…”

Electromagnetic reduction of a pre-formed radius on AA 5754 sheet

“…Oliveira (2007) and Oliveira and Worswick (2003) studied corner fill numerically for an axisymmetric geometry and found that the pressure distribution has a significant effect on the final shape of the material in the corner. Psyk et al (2007Psyk et al ( , 2008 studied sharpening of a feature on a representative full-scale automotive stamping and showed that the process was feasible; unfortunately, they reported deviations from the desired final geometry of the part. Liu et al (2009) showed that the process was feasibly for sharpening features in axisymmetric deep-drawn cups.…”