Advertisement

The effect of coil polarity on electromagnetic forming using a multi-coil system

  • Zhipeng Lai
  • Quanliang Cao
  • Meng Chen
  • Ning Liu
  • Xiaoxiang Li
  • Yujie Huang
  • Xiaotao Han
  • Liang LiEmail author
ORIGINAL ARTICLE
  • 23 Downloads

Abstract

Electromagnetic forming, by combining multiple coils and multiple capacitor banks, is an emerging manufacturing method that can produce flexible spatial-temporal patterns of the Lorentz force to shape metal workpiece. In this process, the polarity of the discharge currents is a key element because it determines the polarity of the magnetic field that is individually induced by each coil, which in turn affects the resulting magnetic field, the Lorentz force, and ultimately the deformation of the workpiece. Aiming to evaluate the potential effects of coil polarity, this paper performed a comparative experimental and numerical study, using a dual-coil system. It is found that the workpiece deformation is sensitive to the coil polarity with respect to both energy efficiency and performance. Furthermore, the analysis of the electromagnetic dynamics shows that the coil polarity would affect the workpiece deformation by altering the electromagnetic interaction between the coils and the workpiece. In this way, both the discharge currents on the coils and the eddy currents on the workpiece would be altered. And consequently, the produced Lorentz forces and thereby the workpiece deformation are affected. The results in this study can be useful for the coil polarity selection that is required in multi-coil forming processes.

Keywords

Electromagnetic forming Flexibility Magnetic field Simulation Dual-coil Multi-coil Electromagnetic interaction 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Funding information

This study was financially supported by the National Basic Research Program of China (2011CB012801) and the China Postdoctoral Science Foundation (2018M632856).

References

  1. 1.
    Mynors DJ, Zhang B (2002) Applications and capabilities of explosive forming. J Mater Process Technol 125-126:1–25CrossRefGoogle Scholar
  2. 2.
    Mamalis AG, Manolakos DE, Kladas AG, Koumoutsos AK (2004) Electromagnetic forming and powder processing: trends and developments. Appl Mech Rev 57:299–324CrossRefGoogle Scholar
  3. 3.
    Daehn GS (2006) High velocity metal forming, ASM handbook, Metalworking: sheet forming. ASM International 14B:405–418Google Scholar
  4. 4.
    Psyk V, Risch D, Kinsey BL, Tekkaya AE, Kleiner M (2011) Electromagnetic forming—a review. J Mater Process Technol 211:787–829CrossRefGoogle Scholar
  5. 5.
    Rohatgi A, Stephens EV, Davies RW, Smith MT, Soulami A, Ahzi S (2012) Electro-hydraulic forming of sheet metals: free-forming vs. conical-die forming. J Mater Process Technol 212:1070–1079CrossRefGoogle Scholar
  6. 6.
    Vivek A, Brune RC, Hansen SR, Daehn GS (2014) Vaporizing foil actuator used for impulse forming and embossing of titanium and aluminum alloys. J Mater Process Technol 214:865–875CrossRefGoogle Scholar
  7. 7.
    Murata M, Suzuki H (1990) Profile control in tube flaring by electromagnetic forming. J Mater Process Technol 22:75–90CrossRefGoogle Scholar
  8. 8.
    Yu H, Fan Z, Li C (2014) Magnetic pulse cladding of aluminum alloy on mild steel tube. J Mater Process Technol 214:141–150CrossRefGoogle Scholar
  9. 9.
    Weddeling C, Walter V, Haupt P, Tekkaya AE, Schulze V, Weidenmann KA (2015) Joining zone design for electromagnetically crimped connections. J Mater Process Technol 225:240–261CrossRefGoogle Scholar
  10. 10.
    Fan Z, Yu H, Li C (2016) Plastic deformation behavior of bi-metal tubes during magnetic pulse cladding: FE analysis and experiments. J Mater Process Technol 229:230–243CrossRefGoogle Scholar
  11. 11.
    Lai Z, Han X, Cao Q, Qiu L, Zhou Z, Li L (2014) The electromagnetic flanging of a large-scale sheet workpiece. IEEE Trans Appl Supercond 24Google Scholar
  12. 12.
    Cui X, Mo J, Li J, Xiao X, Zhou B, Fang J (2016) Large-scale sheet deformation process by electromagnetic incremental forming combined with stretch forming. J Mater Process Technol 237:139–154CrossRefGoogle Scholar
  13. 13.
    Lai Z, Cao Q, Han X, Liu N, Li X, Huang Y, Chen M, Cai H, Wang G, Liu L, Guo W, Chen Q, Li L (2017) A comprehensive electromagnetic forming approach for large sheet metal forming. Procedia Eng 207:54–59CrossRefGoogle Scholar
  14. 14.
    Long A, Wan M, Wang W, Wu X, Cui X, Fang C (2017) Electromagnetic superposed forming of large-scale one-dimensional curved AA2524-T3 sheet specimen. Int J Adv Manuf Technol 92:25–38CrossRefGoogle Scholar
  15. 15.
    Kamal M, Daehn GS (2007) A uniform pressure electromagnetic actuator for forming flat sheets. J Manuf Sci Eng 129:369CrossRefGoogle Scholar
  16. 16.
    J. Shang, Electromagnetically assisted sheet metal stamping, PhD Dissertation, The Ohio State University, Columbus, Ohio, 2006. http://rave.ohiolink.edu/etdc/view?acc_num=osu1158682908
  17. 17.
    Imbert J, Worswick M (2011) Electromagnetic reduction of a pre-formed radius on AA 5754 sheet. J Mater Process Technol 211:896–908CrossRefGoogle Scholar
  18. 18.
    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
  19. 19.
    Shang J, Daehn G (2011) Electromagnetically assisted sheet metal stamping. J Mater Process Technol 211:868–874CrossRefGoogle Scholar
  20. 20.
    Takatsu N, Kato M, Sato K, Tobe T (1988) High-speed forming of metal sheets by electromagnetic force. Japan Society Mechanical Engineering International Journal (JSME) Series III 31:(1)142–148Google Scholar
  21. 21.
    Ahmed M, Panthi SK, Ramakrishnan N, Jha AK, Yegneswaran AH, Dasgupta R, Ahmed S (2011) Alternative flat coil design for electromagnetic forming using FEM. Trans Nonferrous Metals Soc China 21:618–625CrossRefGoogle Scholar
  22. 22.
    Lai Z, Cao Q, Han X, Zhou Z, Xiong Q, Zhang X, Chen Q, Li L (2014) Radial-axial force controlled electromagnetic sheet deep drawing: electromagnetic analysis. Procedia Eng 81:2505–2511CrossRefGoogle Scholar
  23. 23.
    Lai Z, Cao Q, Zhang B, Han X, Zhou Z, Xiong Q, Zhang X, Chen Q, Li L (2015) Radial Lorentz force augmented deep drawing for large drawing ratio using a novel dual-coil electromagnetic forming system. J Mater Process Technol 222:13–20CrossRefGoogle Scholar
  24. 24.
    Lai Z, Cao Q, Han X, Huang Y, Deng F, Chen Q, Li L (2017) Investigation on plastic deformation behavior of sheet workpiece during radial Lorentz force augmented deep drawing process. J Mater Process Technol 245:193–206CrossRefGoogle Scholar
  25. 25.
    Zhang X, Cao Q, Han X, Chen Q, Lai Z, Xiong Q, Deng F, Li L (2016) Application of triple-coil system for improving deformation depth of tube in electromagnetic forming. IEEE Trans Appl Supercond 26Google Scholar
  26. 26.
    Cui X, Mo J, Li J, Xiao X (2017) Tube bulging process using multidirectional magnetic pressure. Int J Adv Manuf Technol 90:2075–2082CrossRefGoogle Scholar
  27. 27.
    Zhou Z, Fu J, Cao Q, Lai Z, Xiong Q, Han X, Li L (2017) Electromagnetic cold-expansion process for circular holes in aluminum alloy sheets. J Mater Process Technol 248:49–55CrossRefGoogle Scholar
  28. 28.
    Cao Q, Han X, Lai Z, Xiong Q, Zhang X, Chen Q, Xiao H, Li L (2015) Analysis and reduction of coil temperature rise in electromagnetic forming. J Mater Process Technol 225:185–194CrossRefGoogle Scholar
  29. 29.
    H. Yu., C. Li., and J. Deng (2009) Sequential coupling simulation for electromagnetic–mechanical tube compression by finite element analysis. J Mater Process Technol 209:707–713CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.Wuhan National High Magnetic Field CenterHuazhong University of Science and TechnologyWuhanChina
  2. 2.State Key Laboratory of Advanced Electromagnetic Engineering and TechnologyHuazhong University of Science and TechnologyWuhanChina

Personalised recommendations