Process Design for Electromagnetic Forming of Magnesium Alloy AZ31 Using FE Simulation
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Date
2016-04-27
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Abstract
Magnesium wrought alloys are outstanding lightweight materials due to their low density
and high specific strength. The low formability of magnesium wrought alloy AZ31 at room
temperature is increased by electromagnetic forming in comparison to quasi-static
forming. For a detailed study of electro-magnetic process a coupled FE simulation must be
performed. In this paper the process design for electromagnetic forming of magnesium
wrought alloy AZ1 using FE simulation is presented.
The complexity of an electromagnetic forming process requires the illustration of
magnetic, thermal and structural dynamic domains. Moreover, it is also necessary to
illustrate the electromagnetic resonant circuit RLC. Short processing time and the strong
dependence of the physical domains to each other requires a coupled FE simulation.
The illustration of resonant circuit and the resulting formation of magnetic field is
carried out in two-dimensional rotationally symmetric model in ANSYS MAPDL using a
suitable material model. As a result time-dependent and location-dependent eddy currents
and Lorentz forces are estimated.
Subsequently, the transmission of the estimated Lorentz forces and joule heat
generation rates to ANSYS LS-DYNA is done. Due to the rotational symmetry of 2D ANSYS
MAPDL model a transformation of the loads on 3D structures can be realized. The
formation of an optimum deformation of a work piece in dependence of a defined die has
been carried out. Here, the influence of different coil designs, die materials and geometries
and RLC parameters was investigated.
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Keywords
electromagnetic forming, magnesium wrought alloy AZ31, FE simulation