Numerical Investigation of Integrating Electromagnetic Forming with Supercritical Fluid -Assisted Polymer Injection Molding
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Date
2025-08-26
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Abstract
Lightweight sheet metal-polymer components with micro- to nanocellular structures offer a
unique combination of structural performance and functional properties. Using
conventional manufacturing approaches requires complex and costly multi-stage
manufacturing routes to realize such components. Moreover, achieving polymer foams with
fine morphology is challenging due to the limitations in precise control over the current
foaming technique. To address this limitation, this study explores the novel concept of
integrating electromagnetic forming with supercritical fluid (SCF)-assisted polymer
injection molding, called the electromagnetic forming injection foaming (EFIF) process. To
investigate the feasibility of this integration, a combined numerical-analytical framework is
developed using Abaqus finite element (FE) software and cell nucleation analytical models.
Simulations are conducted and compared with experimental results to evaluate the influence
of this integration on the electromagnetic stage. The deformation rates extracted from the
Abaqus simulations are incorporated into a set of modified analytical models based on
classical nucleation theory to estimate the pressure drop dynamics. This study provides a
more accurate representation of cell formation within the EFIF process by coupling these
pressure variations with the governing equations for nucleation and growth. The results
demonstrate the feasibility of this integration and its potential to enable precise control over
the SCF-assisted foaming process.
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Keywords
Electromagnetic Forming, Supercritical Fluid-assisted Foaming, Hybrid manufacturing, Micro/Nanocellular Structures, Analytical-Numerical Modeling
Subjects based on RSWK
Magnetumformen, Destraktion, Spritzgießen, Produktionstechnik, Finite-Elemente-Methode, ABAQUS, Mikrostruktur, Nanostruktur