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Direct pulse current electromagnetic forming (DPCEMF): a novel electromagnetic forming technology for aluminum alloy sheet

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Abstract

Discharge coil is the core component of the traditional electromagnetic forming technology. However, the machining of discharge coil is difficult, and the manufacturing cost is expensive. The durability of the coil is also challenged due to the effect of temperature rise, and accumulated coil deformation leads to a change in coil parameters during multiple discharges, which seriously restricts the industrial application of electromagnetic forming. This paper proposes a new electromagnetic forming method, named direct pulse current electromagnetic forming (DPCEMF). The traditional electromagnetic forming method loads the current to the coil, and then, an eddy is inducted on the surface of the workpiece conductor near the coil. However, the new method is a reverse approach, that is, the workpiece is directly loaded with a pulse current, and the surface of the high-conductivity metal block near the workpiece induces an opposite eddy and produces a repulsive electromagnetic force, which in turn causes the high-speed deformation of the workpiece. The discharge coil of conventional electromagnetic forming is replaced with a high-conductivity metal block, which greatly improves the strength, service life, and reliability of the forming system. The DPCEMF process is thermoplastic electromagnetic forming in which heating and electromagnetic forming are conducted simultaneously and completed in microseconds. The method has been well verified by experiments to overcome the forming of a difficult-to-form material, taking a solid step toward realizing the industrial application of electromagnetic forming.

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Availability of data and materials

The datasets generated during the current study are available from the corresponding author on reasonable request.

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Funding

This work was supported by the National Natural Science Foundation of China (Nos. 51705169, 52075197), Key Research and Development Program of Hubei Province of China (Nos. 2020BAB139), Open Research Fund of State Key Laboratory of High Performance Complex Manufacturing, Central South University Kfkt2021-03 and State Key Laboratory of Materials Processing and Die & Mould Technology, HUST (P2020-05).

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Authors and Affiliations

  1. College of Engineering, China Agricultural University, Beijing, 100083, China

    Fei Feng

  2. College of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China

    Jianjun Li & Liang Huang

  3. School of Materials Science and Engineering, Hubei University of Automotive Technology, Shiyan, 442002, China

    Rongchuang Chen

  4. School of Mechanical and Electrical Engineering, Wuhan Institute of Technology, Wuhan, 430205, China

    Suo Fan

Authors
  1. Fei Feng
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  2. Jianjun Li
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  3. Liang Huang
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  4. Rongchuang Chen
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  5. Suo Fan
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Contributions

The material preparation and the experiment research were conducted by FF and SF. Data processing and manuscript preparation were led by FF with contributions from all authors.

Corresponding author

Correspondence to Jianjun Li.

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Feng, F., Li, J., Huang, L. et al. Direct pulse current electromagnetic forming (DPCEMF): a novel electromagnetic forming technology for aluminum alloy sheet. Int J Adv Manuf Technol 121, 6059–6072 (2022). https://doi.org/10.1007/s00170-022-09661-8

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  • DOI: https://doi.org/10.1007/s00170-022-09661-8

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