Skip to main content
SpringerLink
Log in

A comparative study on the effects of boundary constraints on electromagnetic sheet forming

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper investigates the effect of boundary constraints on the plastic deformation behavior of a ∅458 circular sheet metal in an electromagnetic forming process. Both experiments and simulations were conducted on a flat spiral coil system. In the experiments, two different boundary conditions were imposed on the workpiece flange by utilizing a blank holder with and without a draw bead to control the draw-in of the flange. Both the final profile and thickness distribution of the workpiece are sensitive to the boundary constraint, due to the varied draw-in material flow. Furthermore, according to the morphology characteristic of the deformation profile, three typical deformation stages can be recognized, where the thickness reduction at the sheet center only occurs in the first and third stages. This work provides a better understanding of the deformation behavior in the electromagnetic sheet-forming process under varied boundary constraints, which is fundamental for the further development of this process.

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. Miller WS, Zhuang L, Bottema J, Wittebrood AJ, Smet PD, Haszler A, Vieregge A (2000) Recent development in aluminum alloys for the automotive industry. Mater Sci Eng A 280(1):37–49

    Article  Google Scholar 

  2. Psyk V, Risch D, Kinsey BL, Tekkaya AE, Kleiner M (2011) Electromagnetic forming-a review. J Mater Process Technol 211(5):787–829

    Article  Google Scholar 

  3. Balanethiram VS, Hu X, Altynova M, Daehn GS (1994) Hyperplasticity: enhanced formability at high rates. J Mater Process Technol 45(1):595–600

    Article  Google Scholar 

  4. Cui XH, Li JJ, Mo JH, Xiao SJ, Du EH, Zhao J (2011) Numerical simulation of electromagnetic sheet bulging based on FEM. Int J Adv Manuf Technol 57(1–4):127–134

    Article  Google Scholar 

  5. Noh HG, Song WJ, Kang BS, Kim J (2015) Two-step electromagnetic forming process using spiral forming coils to deform sheet metal in a middle-block die. Int J Adv Manuf Technol 76(9–12):1691–1703

    Article  Google Scholar 

  6. Yu HP, Li CF, Jiang HW, Zhao ZH, Deng JH, L ZL, Zhang XF (2008) Research on magnetic pulse sizing of aluminum tube. Int J Adv Manuf Technol 38(11–12):1165–1171

    Article  Google Scholar 

  7. Yu HP, Li CF (2009) Effects of current frequency on electromagnetic tube compression. J Mater Process Technol 209(2):1053–1059

    Article  Google Scholar 

  8. Takatsu N, Kato M, Sato K, Tobe T (1988) High-speed forming of metal sheets by electromagnetic force. JSME Int J 31(1):142–148

    Google Scholar 

  9. Kamal M, Daehn GS (2007) A uniform pressure electromagnetic actuator for forming flat sheets. J Manuf Sci Eng 129(2):369–379

    Article  Google Scholar 

  10. Golowin S, Kamal M, Shang J, Portier J, Din A, Daehn GS (2007) Application of a uniform pressure actuator for electromagnetic processing of sheet metal. Journal of Materials Engineering and Performance 16(4):455–460

    Article  Google Scholar 

  11. Kamal M, Shang J, Cheng V, Hatkevich S, Daehn GS (2007) Agile manufacturing of a micro-embossed case by a two-step electromagnetic forming process. J Mater Process Technol 190(1):41–50

    Article  Google Scholar 

  12. Yu HP, Tong YC (2017) Magnetic pulse welding of aluminum to steel using uniform pressure electromagnetic actuator. Int J Adv Manuf Technol 91(5–8):2257–2265

    Article  Google Scholar 

  13. Shang J, Daehn GS (2011) Electromagnetically assisted sheet metal stamping. J Mater Process Technol 211(5):868–874

    Article  Google Scholar 

  14. Imbert J, Worswick M (2012) Reduction of a pre-formed radius in aluminum sheet using electromagnetic and conventional forming. J Mater Process Technol 212:1963–1972

    Article  Google Scholar 

  15. 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(5):909–915

    Article  Google Scholar 

  16. Daehn GS, Vivek A, Shang JH (2015) Electromagnetically assisted sheet metal stamping and deep drawing. Excellent Inventions in Metal Forming 60:107–112

    Google Scholar 

  17. Cui XH, Li JJ, Mo JH, Fang JX, Zhou B, Xiao XT (2016) Effect of the sheet thickness and current damping exponent on the optimum current frequency in electromagnetic forming. Int J Adv Manuf Technol 85(1–4):843–851

    Article  Google Scholar 

  18. Cao QL, Li L, Lai ZP, Zhou ZY, Xiong Q, Zhang X, Han XT (2014) Dynamic analysis of electromagnetic sheet metal forming process using finite element method. Int J Adv Manuf Technol 74(1–4):361–368

    Article  Google Scholar 

  19. Lai ZP, Cao QL, Zhang B, Han XT, Zhou ZY, 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 222:13–20

    Article  Google Scholar 

  20. Lai ZP, Cao QL, Han XT, Huang YJ, Deng FX, 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 245:193–206

    Article  Google Scholar 

  21. Cui XH, Li JJ, Mo JH, Fang JX, Zhou B, Xiao XT (2016) Incremental electromagnetic-assisted stamping (IEMAS) with radial magnetic pressure: a novel deep drawing method for forming aluminum alloy sheets. J Mater Process Technol 233:79–88

    Article  Google Scholar 

  22. Fang J, Mo J, Li J, Zhou B (2017) Feasibility of electromagnetic pulse-assisted incremental drawing with a radial magnetic force for AA-5052 aluminum alloy sheet. Int J Adv Manuf Technol 88(9–12):3123–3137

    Article  Google Scholar 

  23. Ma HJ, Huang L, Li JJ, Mo JH, Fang JX, Zhou B, Xiao XT (2016) Effects of process parameters on electromagnetic sheet free forming of aluminum alloy. Int J Adv Manuf Technol 96:359–369

    Google Scholar 

  24. Lai ZP, Cao QL, Han XT, Chen M, Li XX, Huang YJ, Chen Q, Li L (2018) Application of electromagnetic forming as a light-weight manufacturing method for large scale sheet metal parts. In: Proceedings of 8th International Conference on High Speed Forming, Columbus (OH), USA, May, 2018.

  25. Mamalis AG, Manolakos DE, Kladas AG, Koumoutsos AK (2004) Electromagnetic forming and powder processing trends and developments. Appl Mech Rev 57(4):299–324

    Article  Google Scholar 

Download references

Acknowledgments

The authors are sincerely grateful for support from the National Basic Research Program of China (973 Program): 2011CB012801 and the China Postdoctoral Science Foundation: 2018 M632856.

Author information

Authors and Affiliations

  1. Wuhan National High Magnetic Field Center, Huazhong University of Science and Technology, Wuhan, Hubei, China

    Ning Liu, Zhipeng Lai, Quanliang Cao, Xiaotao Han, Yujie Huang, Xiaoxiang Li, Meng Chen & Liang Li

Authors
  1. Ning Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhipeng Lai
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Quanliang Cao
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xiaotao Han
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Yujie Huang
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Xiaoxiang Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Meng Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Liang Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Liang Li.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Liu, N., Lai, Z., Cao, Q. et al. A comparative study on the effects of boundary constraints on electromagnetic sheet forming. Int J Adv Manuf Technol 101, 2785–2793 (2019). https://doi.org/10.1007/s00170-018-3098-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-3098-z

Keywords

Search

Navigation