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Experimental and numerical study on patterned emboss forming using electromagnetic forces

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Abstract

In this paper, we propose the use of electromagnetic forming to produce emboss pattern shapes using one forming coil and a single die punch with electromagnetic forces. Considering the noncontact characteristic of the process, the formation of the patterns could be attributed to its high speed. The high impact on the sheet workpiece at a speed of 150–250 m/s produces significant coining pressure, which acts over an area larger than that of conventional forming. In this study, four different patterns were produced on AL 1100-O sheets of area 40 mm × 40 mm and thickness 1.27 mm. The four types of emboss patterns were created by deformation using only one spiral coil. Using the simulation results, an experimental spiral coil with 10 turns was fabricated. Four different patterns were successfully produced on the metal sheet in the experiment. The length and depth of the patterns were measured by three-dimensional scanning relative to the die shape and good agreement was observed. This confirmed that emboss pattern forming by EMF using a single die can be used to replace the costly process of the conventional method.

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Abbreviations

B :

Magnetic flux density

C :

System capacitance

ξ :

Damping factor

I :

System current

J :

Current density

L :

System inductance

ω :

Frequency factor

R :

System resistance

V :

Input voltage

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Authors and Affiliations

  1. Department of Aerospace Engineering, Pusan National University, 2, Busandaehak-ro 63beon-gil, Geumjeong-gu, Busan, 609-735, South Korea

    Hak-Gon Noh, Woo-Jin An, Beom-Soo Kang & Jeong Kim

  2. Industrial Liaison Innovation Center, Pusan National University, 2, Busandaehak-ro 63beon-gil, Geumjeong-gu, Busan, 609-735, South Korea

    Woo-Jin Song

Authors
  1. Hak-Gon Noh
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  2. Woo-Jin An
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  3. Woo-Jin Song
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  4. Beom-Soo Kang
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  5. Jeong Kim
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Corresponding author

Correspondence to Jeong Kim.

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Noh, HG., An, WJ., Song, WJ. et al. Experimental and numerical study on patterned emboss forming using electromagnetic forces. Int. J. Precis. Eng. Manuf. 16, 1447–1454 (2015). https://doi.org/10.1007/s12541-015-0191-1

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  • DOI: https://doi.org/10.1007/s12541-015-0191-1

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