Electromagnetic-assisted calibration for surface part of aluminum alloy with a dedicated uniform pressure coil

  • Wei Liu
  • Xifan Zou
  • Shangyu HuangEmail author
  • Yu Lei


Springback is an inevitable defect of aluminum alloy sheet after conventional stamping process, which directly has an influence on the forming accuracy of part. For a surface part of aluminum alloy, the stamping process was used to complete the preforming process, and then the electromagnetic forming was adopted to calibrate the shape and improve the forming accuracy. A dedicated uniform pressure coil was proposed to quasi-uniformly impose the impulse magnetic pressure on the whole part. The effect of discharge voltage on the springback phenomenon was experimentally and numerically investigated. It was found that the springback defect of surface part was significantly reduced with the discharge voltage increasing. The forming accuracy of surface part was remarkably improved under the discharge voltage of 5 kV. It can be attributed to two aspects: on the one hand, the effective plastic strain level at the bottom of surface part was greatly elevated, and on the other hand, the gap between the tensile stress on the exterior surface and the compressive stress on the interior surface was well decreased.


Electromagnetic forming Surface part Springback Uniform pressure coil 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


Funding information

This project (P2018-013) was supported by State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, China and Jiangsu Key Laboratory of Precision and Micro-manufacturing Technology, Nanjing University of Aeronautics and Astronautics, China.


  1. 1.
    Psyk V, Risch D, Kinsey BL, Tekkaya AE, Kleiner M (2011) Electromagnetic forming-a review. J Mater Process Technol 211:787–829CrossRefGoogle Scholar
  2. 2.
    Vohnout VJ (1998) A hybrid quasi-static/dynamic process for forming large sheet metal parts from aluminum alloys, Ph.D. Thesis, Ohio State UniversityGoogle Scholar
  3. 3.
    Okoye CN, Jiang JH, Hu ZD (2006) Application of electromagnetic-assisted stamping (EMAS) technique in incremental sheet metal forming. Int J Mach Tool Manu 46:1248–1252CrossRefGoogle Scholar
  4. 4.
    Psyk V, Beerwald C, Henselek A, Homberg W, Brosius A, Kleiner M (2007) Integration of electromagnetic calibration into the deep drawing process of an industrial demonstrator part. Key Eng Mater 344:435–442CrossRefGoogle Scholar
  5. 5.
    Liu DH, Li CF, Yu HP (2009) Numerical modeling and deformation analysis for electromagnetically assisted deep drawing of AA5052 sheet. Trans Nonferrous Metals Soc China 19:1294–1302CrossRefGoogle Scholar
  6. 6.
    Shang J, Daehn G (2011) Electromagnetically assisted sheet metal stamping. J Mater Process Technol 211:868–874CrossRefGoogle Scholar
  7. 7.
    Imbert J, Worswick M (2011) Electromagnetic reduction of a pre-formed radius on AA 5754 sheet. J Mater Process Technol 211:896–908CrossRefGoogle Scholar
  8. 8.
    Imbert J, Worswick M (2012) Reduction of a pre-formed radius in aluminum sheet using electromagnetic and conventional forming. J Mater Process Technol 212:1963–1972CrossRefGoogle Scholar
  9. 9.
    Choi MK, Huh H, Park N (2017) Process design of combined deep drawing and electromagnetic sharp edge forming of DP980 steel sheet. J Mater Process Technol 244:331–343CrossRefGoogle Scholar
  10. 10.
    Kamal M, Daehn GS (2007) A uniform pressure electromagnetic actuator for forming flat sheets. J Manuf Sci Eng 129:369–379CrossRefGoogle Scholar
  11. 11.
    Meng Z, Huang S, Hu J, Huang W, Xia Z (2011) Effects of process parameters on warm and electromagnetic hybrid forming of magnesium alloy sheets. J Mater Process Technol 211:863–867CrossRefGoogle Scholar
  12. 12.
    Feng F, Huang S, Hu J, Meng Z, Lei Y (2013) Analysis of the bulging process of an AZ31B magnesium alloy sheet with a uniform pressure coil. Int J Adv Manuf Technol 69:1537–1545CrossRefGoogle Scholar
  13. 13.
    Xu JR, Cui JJ, Lin Q, Li Y, Li CF (2015) Magnetic pulse forming of AZ31 magnesium alloy shell by uniform pressure coil at room temperature. Int J Adv Manuf Technol 77:289–304CrossRefGoogle Scholar
  14. 14.
    Thibaudeau E, Kinsey BL (2015) Analytical design and experimental validation of uniform pressure actuator for electromagnetic forming and welding. J Mater Process Technol 215:251–263CrossRefGoogle Scholar
  15. 15.
    Woodward S, Weddeling C, Daehn G, Psyk V, Carson B, Tekkaya AE (2011) Production of low-volume aviation components using disposable electromagnetic actuators. J Mater Process Technol 211:886–895CrossRefGoogle Scholar
  16. 16.
    Iriondo E, Alcaraz JL, Daehn GS, Gutiérrez MA, Jimbert P (2013) Shape calibration of high strength metal sheets by electromagnetic forming. J Manuf Process 15:183–193CrossRefGoogle Scholar
  17. 17.
    Iriondo E, Gutiérrez MA, González B, Alcaraz JL, Daehn GS (2011) Electromagnetic impulse calibration of high strength sheet metal structures. J Mater Process Technol 211:909–915CrossRefGoogle Scholar
  18. 18.
    Cui X, Yu H, Wang Q (2018) Electromagnetic impulse calibration in V-shaped parts. Int J Adv Manuf Technol 97:2959–2968CrossRefGoogle Scholar
  19. 19.
    Yan S, Huang S, Liu W, Hu J, Lei Y (2017) Experimental and numerical investigation of temperature evolution during electromagnetic pulsed compaction of powders. Powder Technol 306:1–9CrossRefGoogle Scholar
  20. 20.
    Lei Y, Huang S, Liu W, Xiao Y, Hu J, Du X, Zou X (2018) Dissimilar Cu/Al tube joint by EMF-assisted brazing. Int J Adv Manuf Technol 1(1):1–9Google Scholar
  21. 21.
    Livermore Software Technology Corp (2012) EM theory manual - electromagnetism and linear algebra in LS-DYNAGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.School of Materials Science and EngineeringWuhan University of TechnologyWuhanChina
  2. 2.State Key Laboratory of Materials Processing and Die & Mould TechnologyHuazhong University of Science and TechnologyWuhanChina

Personalised recommendations