Investigation of the electromagnetic attractive forming utilizing a dual-coil system for tube bulging

Ouyang, Shaowei; Li, Xiaoxiang; Li, Changxing; Du, Limeng; Peng, Tao; Han, Xiaotao; Li, Liang; Lai, Zhipeng; Cao, Quanliang

doi:10.1016/j.jmapro.2019.11.006

Cited by 42 publications

(25 citation statements)

References 26 publications

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“…This following four models are included in this simulation: global ordinary differential equations (ODEs), magnetic fields, solid mechanics, and moving mesh [20]. Moreover, based on earlier studies [12]- [15], the three-dimensional (3D) model can be simplified to a two-dimensional (2D) axisymmetric model due to the symmetric nature of the coil and plate structure. Further, the precision of this model meets the engineering requirements.…”

Section: Simulation and Analysis A Two-dimensional Axisymmetricmentioning

confidence: 99%

“…Further, the coil usually exhibits a multi-layer, multi-turn structure, which makes it more susceptible to damage and eventually leads to an unstable structure. To resolve this issue, Xiong et al [14] and Ouyang et al [15] improved the single-coil system to a dual-coil system, which has been successfully used in the flanging and the bulging of aluminum alloy tube fittings.…”

Section: Introductionmentioning

confidence: 99%

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A Dual-Coil Method for Electromagnetic Attraction Forming of Sheet Metals

et al. 2020

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Electromagnetic forming is a novel technology in which a coil is used to generate a pulsed Lorentz force for shaping sheet metal pieces. However, the Lorentz force between the coil and the sheet metal is generally repulsive due to the Lenz's Law, which limits the practical application of this technology. To break this bottleneck, a dual-coil method is proposed to generate attractive Lorentz force, which is then used to form sheet metals. The theoretical principle of this method is presented, and an infinite element model is established to simulate the forming effect. The simulation results show that an A1060-O plate with a diameter of 140 mm and thickness of 1 mm can be attractively shaped under this method. The maximum axial displacement of the plate reaches 2.74 mm. Unfortunately, a dent exists in this situation. Further analysis indicates that this dent can be eliminated by increasing the inner and outer diameters of the coils. Further, it is found that when the capacitance value of the long pulse-width discharge circuit is set to 5.6 mF and the initial discharge voltage is set to 10.690 kV, the sheet metal attains the best shape.

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Section: Simulation and Analysis A Two-dimensional Axisymmetricmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Dual-Coil Method for Electromagnetic Attraction Forming of Sheet Metals

et al. 2020

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“…Lightweight alloys are widely used in several applications including aerospace, automotive industry and other fields [1]. For example, the weight of the aircraft body is reduced by 5kg, while the effective commercial load can be increased by 50kg when the body is made of lightweight alloy [2]. Similarly, when lightweight alloy material is used in manufacturing cars, the weight is reduced by 10%, and the fuel consumption is reduced by 6% to 8% [3].…”

Section: Introductionmentioning

confidence: 99%

“…It is to be note that in [2], the driving coil is placed inside the pipe, which makes it difficult to achieve effective bulging. In [14], a double-coil axial compression pipe electromagnetic bulging is proposed, which simultaneously realizes the axial and the radial bidirectional loading.…”

Section: Introductionmentioning

confidence: 99%

“…In this method the driving coils are placed on the top and bottom of the pipe fitting to provide reasonable electromagnetic force distribution. However, in the proposed topologies in [2] and [14], the height of the bulging coil is much larger than the height of the pipe which results in a higher radial electromagnetic force at the end of the pipe than at the middle section which reduces the effectiveness of the proposed methods. Therefore, the introduction of the auxiliary coil in this paper, will deteriorate the radial electromagnetic force at the pipe ends and helps improve the uniformity of the pipe.…”

Section: Introductionmentioning

confidence: 99%

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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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