Produce a large aluminium alloy sheet metal using electromagnetic-incremental forming (EM-IF) method
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Date
2012-07-18
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Abstract
The conventional electromagnetic forming processing can’t shape large parts due to limitation
of the strength of working coil and the capacity of capacitor bank. In this paper, a novel
technology named electromagnetic-incremental forming (EMIF) has been proposed. A small
working coil moves along the special motion trail and many small electromagnetic pulses
energy are used to form a larger aluminum alloy sheet. The effect of vent holes, discharge
voltage on sheet final profiles are analyzed. In addition, two discharge times with varying
value of discharge voltage is used to obtain better final sheet profiles. The effect of the
previous discharge on the second one is also analyzed. Then, a 3D sequential coupling
method is used to calculate the magnetic force on the sheet and analyze the forming process.
In the latter deformation, the deformation information is also considered from the former one,
such as the deflection, velocity, stress, strain, et al. The simulation values are in better
agreement with the experimental ones. This work demonstrates that the new technology
offers an ability to form large and complex components with a small working coil and small
discharging energy of the electromagnetic machine. Moreover, the simulation method can be
used for more complex forming system.
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Keywords
3D numerical simulation, electromagnetic-incremental forming, flexible manufacturing