Skip to main content
SpringerLink
Log in

Designing of field shaper for the electro-magnetic crimping process

  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

Design of a field shaper plays an essential role in the electromagnetic crimping process. It needs to be designed in such a manner that maximum magnetic field is concentrated at the active working zone. Simultaneously it is essential to take care of the mechanical strength of the field shaper so that the von Mises stress acting over the field shaper should always be lower than the strength of the material used for making field shaper. In this manuscript, numerical and experimental work is carried out in the variation of the effective height of the field shaper, to get the most suitable effective working zone height for maximum magnetic pressure acting over the workpiece. Research is carried out over the electrical interconnectors as an application, to achieve maximum crimping of the terminal over the wire strands. Results like the current density Von-Mises stress, magnetic field, Lorentz force, terminal deformation, and contact length are discussed in detail. These results will help to design a field shaper for different industrial applications.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. S. F. Golovashchenko, Material formability and coil design in electromagnetic forming, Journal of Materials Engineering and Performance, 16(3) (2007) 314–320.

    Article  Google Scholar 

  2. A. K. Rajak, R. Kumar, H. Basumatary and S. D. Kore, Numerical and experimental study on effect of different types of field-shaper on electromagnetic terminal-wire crimping process, International Journal of Precision Engineering and Manufacturing, 19(3) (2018) 453–459.

    Article  Google Scholar 

  3. V. Psyk, D. Risch, B. L. Kinsey, A. E. Tekkaya and M. Kleiner, Electromagnetic forming—A review, Journal of Materials Processing Technology, 211(5) (2011) 787–829.

    Article  Google Scholar 

  4. A. K. Rajak and S. D. Kore, Experimental investigation of aluminium-copper wire crimping with electromagnetic process: Its advantages over conventional process, Journal of Manufacturing Processes, 26 (2017) 57–66.

    Article  Google Scholar 

  5. R. Chaharmiri and A. F. Arezoodar, The effect of various stepped field shaper on magnetic pressure and radial displacement in electromagnetic inside bead forming: Experimental and simulation analysis using maxwell and abaqus software, Journal of Manufacturing Science and Engineering, 139 (2017) 061003–1–6.

    Article  Google Scholar 

  6. H. Yu, C. Li, Z. Zhao and Z. Li, Effect of field shaper on magnetic pressure in electromagnetic forming, Journal of Materials Processing Technology, 168 (2005) 245–249.

    Article  Google Scholar 

  7. H. Yu, Z. Xu, Z. Fan, Z. Zhao and C. Li, Mechanical property and microstructure of aluminum alloy-steel tubes joint by magnetic pulse welding, Materials Science & Engineering A, 561(2013) 259–265.

    Article  Google Scholar 

  8. H. Suzuki, M. Murata and H. Negishi, The effect of a field shaper in electromagnetic tube bulging, Journal of Mechanical Working Technology, 15 (1987) 229–240.

    Article  Google Scholar 

  9. P. L. Eplattenier, G. Cook, C. Ashcraft, M. Burger, J. Imbert and M. Worswick, Introduction of an Electromagnetism Module in Ls-Dyna for Couple Mechanical-Thermal-Electromagnetic Simulations, Steel Research International, 80(5) (2009) 351–358.

    Google Scholar 

  10. A. C. Jeanson, F. Bay, N. Jacques, G. Avrillaud, M. Arrigoni and G. Mazars, A coupled experimental/numerical approach for the characterization of material behaviour at high strain-rate using electromagnetic tube expansion testing, International Journal of Impact Engineering, 98 (2016) 75–87.

    Article  Google Scholar 

  11. J. P. M. Correia, M. A. Siddiqui, S. Ahzi, S. Belouettar and R. Davies, A simple model to simulate electromagnetic sheet free bulging process, International Journal of Mechanical Sciences, 50 (2008) 1466–1475.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Materials Science and Engineering, The Ohio State University, Columbus, USA

    Ashish K. Rajak

  2. Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, India

    Ramesh Kumar

  3. Department of Mechanical Engineering, Indian Institute of Technology Goa, Goa, India

    Sachin D. Kore

Authors
  1. Ashish K. Rajak
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ramesh Kumar
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Sachin D. Kore
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Ashish K. Rajak.

Additional information

Recommended by Associate Editor Seok-min Kim

Ashish Rajak received his Ph.D. in Mechanical Engineering from IIT Guwahati, India. Currently, he is working as a Post Doc at the Impulse Manufacturing Lab (Glenn Daehn Lab), The Ohio State University, USA. His main research interest includes electromagnetic forming, joining and powder compaction using experimental and simulation approaches.

Ramesh Kumar received his Ph.D. in Mechanical Engineering from IIT Guwahati, India. Currently, he is working as an Assistant Professor in Saharsa College of Engineering, Bihar, India. He works in electromagnetic crimping, cladding, and forming.

Sachin D Kore is currently a faculty in the Mechanical Engineering Department, Dean of Academic Affairs and Student Affairs, IIT Goa, India. He specializes in electromagnetic pulse welding and forming, modeling of the electromagnetic pulse welding process and friction stir welding.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Rajak, A.K., Kumar, R. & Kore, S.D. Designing of field shaper for the electro-magnetic crimping process. J Mech Sci Technol 33, 5407–5413 (2019). https://doi.org/10.1007/s12206-019-1035-1

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-019-1035-1

Keywords

Search

Navigation