Proposal for a Test Bench for Electromagnetic Forming of Thin Metal Sheets

Abstract

This paper presents a proposal to build a test bench for electromagnetic forming processes. The project considers the analysis of the electrical circuit and forces involved in the system for selection of low voltage capacitors, resistors, buses, main discharge switch and material choice for actuator s insulation and rigidity, considering also the manufacturing process of actuators and dies. Among the aspects considered for the design, energy efficiency has been prioritized by the use of non-conducting material to the dies. Main switches by mechanical contact and spark gap types were used and its wear and functionality was assessed. Free bulging experiments were performed with aluminium AA1100 plates for a system configured with a flat coil actuator. Test measurements of electric currents in the coil actuator with and without the workpiece as the secondary circuit were performed, as well as an evaluation of wear and functionality of the system. It is observed that the main switch discharge is one of the most critical items of the system.