On the Significance of the Die Design for Electromagnetic Sheet Metal Forming

Abstract

Electromagnetic Forming is a high speed forming process using a pulsed magnetic field to form metals with high electrical conductivity, such as copper or aluminium alloys. During the process, typical pressure peaks up to 200 MPa and velocities in the range of 300 m/s can be achieved. As significant process parameters the pressure maximum as well as the local and temporal varying pressure distribution have been identified. As of a certain drawing depth and distance between workpiece and tool coil, the pressure does not act any longer on the workpiece, but the deformation process is still driven by the inertia forces. It has been found out that the velocity distribution within the sheet metal during the forming stages as well as at the time of impact with a die significantly influences the forming result. Additionally, a special undesired effect is the rebound behaviour of flat workpiece areas being in contact with the die. To investigate the influence capability of the die concerning this effect, the parameters stiffness and damping properties have been varied by means of simulation using a mechanical substitute model.