Alternative flat coil design for electromagnetic forming using FEM

Electromagnetic forming （EMF） is a high velocity forming process that uses impulse magnetic force. Coil is an important component of EMF system which needs to be designed depending on application. Flat spiral coils are generally used for electromagnetic forming of sheet metals. However, with this type of coil the central portion of the workpiece experiences marginal magnetic force. This leads to in-sufficient deformation at this portion and other problems like air entrapment. In this study, a conceptual design of flat coil was proposed for better distribution of magnetic forces over the workpiece. Comparative analysis of distribution of magnetic force, magnetic field and current density using the proposed and the existing coil designs were carried out using FEM. The result indicates that the proposed coil design produces comparatively better magnetic force distribution over the workpiece. Calculation of self-inductance of such coils was also carried out and was compared with FE simulation.

Finite element modeling and experiment for behavior estimation of AlMn0.5Mg0.5 sheet during electromagnetic forming

The electromagnetic forming is a procedure of high-speed processing,which favors the increase of the formability of some plastically deformed metals.In order to evaluate the capacity of some light metals,such as aluminum and its alloys,to be deformed through this procedure,it is useful to know the stress and strain state that occurs in the material during forming.In this work,the modeling of stresses and strains in electromagnetically deformed AlMn0.5Mg0.5 sheet was made.The modeling was achieved using the finite element method and it was verified through experimental tests.To determine the residual stresses,the X-ray diffraction method was used.The strains were established by measuring the displacements of the nodes in the network inscribed on the specimen by means of three coordinates measuring machine.A good agreement between the modeling results and experimental data was found.

INSIDE BEADING OF A HEXAGONAL TUBE BY ELECTROMAGNETIC FORMING

In this paper local compressive deforming of a hexagonal tube of aluminum (JISA1050) is investigated by an electromagnetic forming. The hexagonal tubes are annealed for 1h. at 400℃， which have 55mm width with 1mm thickness, and 10mm corner edius. The deformed ation of the hexagonal tube, i.e., bead width, is 10, 15, 20mm, respectively. The magnetic flux density in the gap between the field shaper and the external surface of hexagonal tube is measured, and the result is that the magnetic flux density for a given voltage is almost identical along the gap) and decreases with increasing the gap. The profiles and the strain distribution of the hexagonal tube de- formed are affected by the change Of the charging voltage and the dimensions of a bead width. The greater compressive strum in the cireuwtrential direction is develOPed on plane part near corner,while tensile strain on the corner occurs. A metallic block is inserted inside the hexagonal tube so that uniform profile can be obtained. The simulation of the forming is performed by a finite-element method and compared with the experimental results.

The Pairing Analysis Improvement of Magnetized Structure in Electromagnetic Bulging Process in Case of Tube with Field Shaper

In the current practical science, the accuracy in the formability of metal alloys being the goal when using electromagnetic forming (EMF) technology, which is a high-speed processing technology that uses Lorentz forces to achieve plastic deformation of sheet metal;according to the previous analysis, the results have shown that in most cases, the Lorentz force acting on the workpiece (metal) is not uniform, there are uneven axial deformations of the metal plates which prevent the rapid advancement of today’s technology. In this article, we presented some advanced analyzes which will lead us to improve the technical solution for the problems of non-uniform axial deformations of the metals in the traditional tube electromagnetic forming technology (EMF). A field shaper is used as a practical forming tool to influence the magnetic field and magnetic pressure distribution, thereby improving the forming ability and result during the electromagnetic forming (EMF) process and we see that induced eddy current control is realized by changing the structural parameters of the magnetic field shaper;which improves the strength and controllability of the magnetic force that acts on the workpiece;thereby a greater radial magnetic pressure can be achieved with field shaper than the case without it;the field shaper regulates the electromagnetic force, the distribution of the magnetic pressure decreases, and the uniform force area of the tube increases which effectively enhances the uniform range of the pipe electromagnetic bulging and the electromagnetic induction coupling between the coil and the metallic workpiece is generally required to produce the Lorentz forces. Using COMSOL Multiphysics® simulation software helped us to accurately represent the real world, simulating multiple physical effects that happened in this model during the process.

Neutral Pion Electromagnetic Form Factor as a Bound System of 3 + 1 Dimensional QCD

We investigate a neutral pion electromagnetic form factor in momentum space and obtain Gaussian-like function for it. The characteristic form of our neutral pion electromagnetic form factor is consistent with the results published by Jefferson Lab Hall A Collaboration. .

3D modeling and deformation analysis for electromagnetic sheet forming process

Electromagnetic forming （EMF） is a high-speed forming method which can be quite effective in increasing the forming limits of metal sheet. However, the EMF process is complicated due to magnetic-structure coupling analysis. Numerical simulation offers an opportunity to overcome the problem. Nevertheless, most present models for EMF process are limited to 2D axisymmetric model. So, a three-dimensional （3D） finite element model was established to analyze the electromagnetic sheet bulging. The contact between the sheet and the die and the effect of sheet deformation on the magnetic field analysis were both taken into consideration during the forming process. The simulation results of deflection at the sheet center and 20 mm away from the center were in agreement with the experimental ones. The plastic strain energy and plastic strain were analyzed.

A moment-based stochastic edge-based smoothed finite element method for electromagnetic forming process

In this paper, a novel stochastic method named as the moment-based stochastic edge-based finite element method(MSES-FEM)is proposed to deal with the uncertain electromagnetic problems. First, electromagnetic and mechanical field are formulated by smoothed Galerkin Weak Form under edge-based smoothed finite element method(ES-FEM) scheme. The moment analysis is then applied to obtain the first four moments of the responses and to observe the effects of each random variable on electromagnetic field responses. The maximum entropy theory is employed to calculate the probability density functions(PDFs) of the responses. A quasi-static electromagnetic problem and a practical electromagnetic forming problem(EMF) are performed. The proposed method successfully solves stochastic electromagnetic forming analysis under the uncertain parameters. Numerical results obtained by the proposed MSES-FEM are quite satisfactory with the ones by the Monte Carlo simulation(MCS).

Magnetic pressure in electromagnetic tube forming with echelon coil

The effects of geometrical characteristics of echelon coil on the magnetic pressure distribution and their contribution to the final shape of parts were focused and investigated through experiments and numerical simulation using FEM software ANSYS. The results show that the geometrical characteristics of echelon coil play a key role in controlling the magnetic pressure acting on the tube. They show a hump-like distribution near the interface between bigger diameter region and transition region of echelon coil, and affect the final shape of tubular parts then. With the reduction of relative diameter, the magnetic pressure in smaller diameter region decreases and its distribution gradient in transition region increases. With the augment of relative length, the magnetic pressure increases in bigger diameter region, while it almost remains constant in smaller diameter region, and the gradient in transition region enhances sharply. The distribution of magnetic pressure in the axial direction of tube agrees well with the profile of specimen.

Study of Magnetic Force Distribution for Electromagnetic V-shape Bending Forming of Small Size Flat Sheet

Electromagnetic V-shape bending of small size sheet blank is investigated numerically and experimentally. Three-dimensional electromagnetic field models are established to calculate the magnetic force distribution on the sheet by software ANSYS / EMAG. Series of electromagnetic V-shape bending forming experiments are presented,in which small size uniform pressure coil and big size round flat spiral coil are used. The results show that small size uniform pressure coil is not suitable for electromagnetic forming of small size flat sheet,and the coil is susceptible to failure such as bulging,ablation and cracking. When the plane dimension of round flat spiral coil is bigger than sheet blank sizes,the induced current crowding effect will be resulted which seriously influence the magnetic force distribution on the sheet. In this case,magnetic force distribution can be adjusted through the change of the relative position between coil and sheet,the desired deformation can be obtained finally. Therefore,big size round flat spiral coil can be well applied to electromagnetic V-shape bending forming of small size flat sheet.

Magnetic force distribution and deformation law of sheet using uniform pressure electromagnetic actuator

The distribution of magnetic forces and current on sheet and coil was analyzed in detail according to the structural parameter of the coil which was invalid.The result shows that the current direction based on simulation result agrees with the principles of uniform pressure electromagnetic actuator.The reason for coil failure was proposed.Then the magnetic forces on the sheet were input into an explicit finite element software ANSYS/LS-DYNA to analyze the deformation law of the sheet.

Solution of the Nucleon Structure Problem from a Field Theory of Fermions and Bosons and the Origin of the Proton Stability

A bound state formalism derived from a fermion-boson symmetric Lagrangian has been used to calculate the nucleon masses, the charge neutrality of the neutron, the magnetic moments and the electromagnetic form factor ratios μpGEp/GMpand μnGEn/GMn. A quantitative description is obtained, assuming a mixing of a scalar bound state of 3(f f¯)fstructure with its corresponding vector (f f¯)fstate (f indicating massless elementary fermions). Only a few parameters are needed, mainly fixed by energy and momentum conservation. The nucleon stability is explained by an extra binding in the confinement potential, negative for electric and positive for magnetic binding of the proton, and opposite for the neutron. The stronger electric extra binding of the proton allows a decay of the neutron to proton and electron.

Electromagnetic Expansion and Fragmentation of Hollow Aluminium 5052 Tube

Electromagnetic forming is a high-speed forming technology by which hollow profiles can be compressed or expanded. It is done with a pulsed magnetic field to apply Lorentz’ forces at electrically conductive material. Electromagnetic hollow tube expansion is limited by the fragmentation tendency. This work attempts to use a combination of analytical and computational approach to compute the net tangential stress during tube expansion. A simplified analytical framework to estimate the temporal evolution of plastic stresses present in aluminium alloy AA5052 at low and high applied magnetic pressures is developed based upon dynamic imaging. The time resolved images captured using current synchronised high speed camera record the overall dimensional changes of the tube that is validated by multi-physics simulation of expansion process. Imaging of hollow tube expansions at two selected peak currents has been carried out at various current levels in the range 76 - 160 kA. The direct visualisation of the increase in the tube diameter at two current levels provided a comparison of the developing net tangential stresses in the hollow tube during the undamaged and fragmented expansion. Imaging of tube expansion also facilitates the estimation of the strain rate experienced by the tube and was in the range of ~1700 s-1 to ~1200 s-1. The propensity of fragmentation was found to be due to the level and duration of generated tangential stresses above the yield stress during expansion of the aluminium tubes. Presented study provides a mean of exploiting the enhanced formability of aluminium alloys using electromagnetic forming.

EFFECT OF VELOCITY ON DUCTILITY UNDER HIGH VELOCITY FORMING

The ring expansion procedures over various forming velocities are calculated with ANSYS software in order to show the effect of forming velocity on ductility of rate insensitive materials. Ring expansion procedures are simplified to one-dimensional tension by constraining the radial deformation, with element birth and death method, fracture problem of circular ring are considered. The calculated results show that for insensitive materials of 1060 aluminum and 3A21 aluminum alloy, fracture strain increases corresponding to the increase of forming velocity. This trend agrees well with experimental results, and indicates inertia is the key factor to affect ductility; With element birth and death methods, fracture problems can be solved effectively. Experimental studies on formability of tubular workpieces are also conducted, experimental results show that the formability of 1060 aluminum and 3A21 aluminum alloy under electromagnetic forming is higher than that under quasistatic forming, according to the characteristics of electromagnetic forming, the forming limit diasrams of the two materials tube are also built respectively, this is very important to promote the development of electromagnetic forming and guide the engineering practices.

Influence of hydrogen content on room temperature compressive properties of Ti-6Al-4V alloy at high strain rate

Electromagnetic forming tests were done at room temperature to reveal the influence of hydrogen content on the compressive properties of Ti-6Al-4V alloy at high strain rate. Microstructure was observed to reveal the mechanism of hydrogen-enhanced compressive properties. The experimental results indicate that hydrogen has favorable effects on the compressive properties of Ti-6Al-4V alloy at high strain rate. Compression of Ti-6Al-4V alloy first increases up to a maximum and then decreases with the increase of hydrogen content at the same discharge energy under EMF tests. The compression increases by 47.0% when 0.2% (mass fraction) hydrogen is introduced into Ti-6Al-4V alloy. The optimal hydrogen content for cold formation of Ti–6Al–4V alloy under EMF was determined. The reasons for the hydrogen-induced compressive properties were discussed.

Effects of temperature on the mechanical properties of Ti6Al4V powder compacts prepared by magnetic pulse compaction

The effects of temperature （0-500°C） on the compressive strength,hardness,average relative density,and microstructure of Ti6Al4V powder green compacts prepared by magnetic pulse compaction were investigated.The results show that with increasing heating temperature,the compressive strength first increases and then decreases with the maximum value of 976.74 MPa at 400°C.The average relative density and hardness constantly increase,and their values reach 96.11% and HRA 69.8 at 500°C,respectively.The increase of partial welding is found among the junctions of particles inside the compacts; there is no obvious grain growth inside the compacts within the temperature range.

Quasi-static-dynamic formability of AA5052-O sheet under uniaxial and plane-strain tension

An experimental study on the quasi-static-dynamic formability specified in electromagnetically assisted sheet metal stamping(EMAS)was presented.A series of uniaxial and plane-strain tensile experiments were carried out on AA5052-O sheet by using a combined quasi-static stretching and pulsed electromagnetic forming(EMF)method.Failure strains representing formability beyond conventional quasi-static forming limits are observed under both uniaxial tensile and plane-strain states.The total forming limits of the as-received aluminum alloy undergoing both low and high quasi-static pre-straining are almost similar in quasi-static-dynamic deformation.Ultimate total formability seems to depend largely on the high-velocity loading conditions.Thus, it appears that for quasi-static-dynamic deformation,the quasi-static pre-straining of material is not of primary importance to the additionally useful formability.These observations will enable to develop forming operations that take advantage of this improvement in formability,and will also enable the use of a quasi-static preform fairly close to the quasi-static forming limits without weakening its total formability for design of an EMAS process in shaping large aluminum shell parts like auto body panels.

DYNAMIC COMPACTION OF PURE COPPER POWDER USING PULSED MAGNETIC FORCE

The compaction of pure Cu powder was carried out through a series of experiments using dynamic magnetic pulse compaction, and the effects of process parameters, such as discharge energy and compacting direction, on the homogeneity and the compaction density of compacted specimens were presented and discussed. The results indicated that the compaction density of specimens increased with the augment of discharge voltage and time. During unidirectional compaction, there was a density gradient along the loading direction in the compacted specimen, and the minimum compaction density was localized to the center of the bottom of the specimen. The larger the aspect ratio of a powder body, the higher the compaction density of the compacted specimen. And high conductivity drivers were beneficial to the increase of the compaction density. The iterative and the double direction compaction were efficient means to manufacture the homogeneous and high-density powder parts.

Effect of Various Field Shapers on Magnetic Pressure in Electromagnetic Inward Tube Forming

In this paper,the influence of various field shapers and their shapes on the distribution of the magnetic flux densities and applied forces on the work-piece in the electromagnetic inward tube forming are studied numerically using the FEA software MAXWELL.First the model was verified with experimental results and thereafter four kinds of field shapers(conical,cylindrical,concave and convex)were considered.Effects of their geometries,such as air gap between field shaper and tube work-piece,height of the step in single and multiple stepped field shaper on magnetic flux densities and magnetic pressures were studied.The results of this research can be applied to design field shaper,tube compression technology,and improve the efficiency of the coil.It is seen that magnetic force decreases if height of step in convex field shaper increases but effective forming region enlarges.Decreasing air gap has also a positive influence on magnetic field increase.Though the object of this research is limited to field shaper for inward tube forming,the results can also be applied to the field shaper for tube bulging.

Microstructure and mechanical properties of Ti6Al4V powder compacts prepared by magnetic pulse compaction

Ti6Al4V powder compaction was performed by using magnetic pulse compaction in air at 200℃.Effects of process parameters such as voltage,capacitance,discharge times on the microstructure,compressive strength,hardness and relative density of compacts were investigated.The experimental results show that the relative density,hardness and compressive strength of compacted specimens increase with increasing voltage.In addition,the relative density and compressive strength of compacted specimens increase with the augmentation of capacitance in the range investigated.The relative density increases,the hardness firstly increases and then tends to be a fixed value;and the compressive strength firstly increases and then decreases from one to five times compaction.Both values of the hardness and compressive strength reach the maxima of HRA 69.1 and 1 062.31 MPa,at three times compaction,respectively.There are pores in and between particles.

Nucleon Form Factors and N-△ Transitions in a Hypercentral Constituent Quark Model with Meson Cloud

We study the nucleon form factors and the nucleon-△（1232） transitions in a framework of hypercentral constituent quark model. The pion meson cloud effect is taken into account explicitly. Our results show that the pion cloud contributes substantially to the nucleon form factors as well as to the helicity amplitudes of △（1232）, and it gives an improved agreement compared to the experimental.