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Investigation of accurate forming of a semi-ellipsoidal shell part by an electromagnetic forming method

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

Abstract

Forming a sheet into a predesigned die cavity is an effective way to improve the dimensional accuracy of deformed parts. However, it is difficult to obtain good die-fitting quality for workpiece deformed at high speed during the one-time discharge electromagnetic forming (EMF) process. To address this challenge, a numerical simulation model was established to help optimize the forming process that affects the die-fitting quality in the formation of a semi-ellipsoid shell part. Then, experiments were conducted according to the optimized forming process. Finally, the dynamic deformation behavior of the workpiece was revealed. The results showed that the drawing deformation mode can effectively improve the die-fitting quality as well as the effective plastic strain distribution of the shell part compared with the bulging deformation mode. Moreover, reducing the initial blank diameter is a more effective way to improve draw-in compared with adjusting the blank holder force. Furthermore, a semi-ellipsoid shell part was manufactured with a maximum die-fitting gap of no more than 1.4 mm at a one-time discharge voltage of 11.5 kV. The deviation was only 1.45% of the maximum forming height. The results provide a foundation for forming a large semi-ellipsoidal shell part by the one-time discharge EMF method.

Keywords

Accurate forming One-time discharge Electromagnetic sheet forming Deformation behavior 

Notes

Funding information

This work was supported by the National Basic Research Program of China (973 Program, Grant No. 2011CB012801), the National Key Research and Development Program of China (Grant No. 2016YFA0401701), and the China Postdoctoral Science Foundation (2018 M632856).

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Copyright information

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

Authors and Affiliations

  • Ning Liu
    • 1
    • 2
  • Zhipeng Lai
    • 1
    • 2
  • Quanliang Cao
    • 1
    • 2
  • Liang Li
    • 1
    • 2
  • Xiaotao Han
    • 1
    • 2
  • Yujie Huang
    • 1
    • 2
  • Meng Chen
    • 1
    • 2
  • Xiaoxiang Li
    • 1
    • 2
  • Yiliang Lv
    • 1
    • 2
    Email author
  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

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