Numerical Simulation of Magnetic Pulse Welding
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Date
2012-07-17
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Alternative Title(s)
Insights and Useful Simplifications
Abstract
The increasing demand for the use of lightweight materials and part designs, especially in
the automotive industry, is a driving factor for the development of new joining techniques.
One of the main challenges is joining of dissimilar materials. Magnetic pulse welding
(MPW), a high-velocity, cold forming technique is a possible solution, as it is known for its
ability to join dissimilar metals. To determine the potential of this technology for a certain
application, simulation techniques have become a major part of the research process.
This paper shows some ways how to use simulation tools effectively to analyse the
coil and the field shaper-geometry as well as to study their effect on the workpiece. The
predictability of current distributions, resulting magnetic pressures and general process
efficiency are discussed. Furthermore it is described which simplifications may be applied
in order to reduce the simulation time for transient calculations. Especially aspects of the
transient force evolution during a pulse are discussed and comparisons to simplified timeharmonic
results are given.
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Keywords
finite element method (FEM), modelling, simulation