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Development of One-dimensional Semi-coupled Field Electromagnetic-Thermal Model on Electromagnetic Tube Forming

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Abstract

Electromagnetic forming is an impulse or high speed forming technology using a pulsed magnetic field to apply Lorentz forces to parts preferably made of a highly electrically conductive material with no mechanical contact and no working medium. Thus, the hollow sections can be compressed or expanded and flat or preformed three-dimensional sheets can be shaped and assembled as well as cutting operations can be performed. Although electromagnetic forming has been a known technology for several decades, a current revival of interest is brought to its industrial application, favored by its potential to form aluminum and copper alloys and other materials with low formability. Along with this interest, the demand for simulation tools is increasing. The main achievement of this research is to present a simple and accurate theoretical model that can provide a bridge between electrical data and thermal data in the process of electromagnetic tube forming. The proposed model estimates the temperature of the workpiece faster than finite element or experimental models. The present research aims to develop one-dimensional theoretical model of a semi-coupled electrothermal field for the analysis of electromagnetic tube forming. The electromagnetic forming process divided into two sub-models that are solved together: Based on Maxwell’s equations electromagnetic model, and linked thermomechanical part behavior model. In this work, special attention is devoted to the study of the most relevant process parameters, with emphasis on their meaning, effects, and mutual interaction. To assess the performance of the proposed approach, the results are compared with the finite element method-ANSYS tool and experimental data, in order to assess the robustness and precision of the proposed model. The results obtained show a good correlation between the proposed theoretical model than the numerical values and experimental data by 7% difference, making it possible to validate the methodology developed.

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Not applicable.

Code Availability

PC Matlab, Ansys.

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  1. Department of Mechanical Engineering, Sanandaj Branch, Islamic Azad University, P.O.B. 618, Sanandaj, Iran

    Hossein Nouri

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  1. Hossein Nouri
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Nouri, H. Development of One-dimensional Semi-coupled Field Electromagnetic-Thermal Model on Electromagnetic Tube Forming. Process Integr Optim Sustain 6, 471–482 (2022). https://doi.org/10.1007/s41660-022-00225-7

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