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.

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.

Effect of plastic strain and forming temperature on magnetic properties of low-carbon steel

Claw poles are a key component of automobile generators.The output power performance of the generator is very dependent on the magnetic properties of its claw poles.Plastic deformation is known to significantly change the magnetic behavior of ferromagnetic materials in claw poles.In this paper,changes in the magnetic properties of low-carbon steel,used for claw pole components due to their plastic deformation,were investigated for different strains and temperatures.Ring-shaped material samples were prepared by machining and their magnetic properties were measured.The surface roughness was first evaluated and a machining process with an arithmetic average of roughness Ra 1.6μm was selected as enabling the lowest measurement error.Hysteresis loops at different applied magnetic fields of the material were obtained for different plastic strains and forming temperatures.The magnetic parameters of magnetic flux density,coercivity,and remanence were obtained and compared with magnetic flux density as the primary focus.Results showed that machining,cold forming,and hot forming all led to lower magnetic flux density,larger coercivity,and smaller remanence.Magnetic flux density showed a sharp decrease at the start of plastic deformation,but as the strain increased,the decreasing trend gradually reached a constant value.The decrease was much larger for cold forming than for hot forming.For example,at 500 A/m,the degradation of magnetic flux density with a reduction percentage of 5%at room temperature was about 50%,while that of hot forming at 1200°C was about 10%.Results of this research may provide a reference for the future process design of hot-forged claw poles.

Glass forming ability, microstructure and magnetic property of NdAlNiCuFe alloys

The glass forming ability (GFA), microstructure and magnetic property in (Nd60Al10Ni10)Cu20-xFex (0≤ x≤ 20) alloys were investigated by using X-ray diffraction (XRD), differential scanning calorimetry (DSC), high resolution transmission electron mi- croscopy (HRTEM) and magnetic property measurement. It is shown that the GFA of the alloys decreases with Fe content. The sam- ples for bulk cylinders with x≤10 show a distinct endothermic peak in the DSC traces due to a glass transition in the range of 421-438 K. With further increasing Fe, the glass transition is masked by the crystallization. The microstructure of the Nd-based alloy can change progressively from full glassy state into composite state with nanocrystalline particles in the glassy matrix indicating the glass forming ability degrades with increasing Fe. The average size of nanocrystals increases with Fe and the distribution changes from homogenous to heterogeneous. The magnetic property varies from paramagnetic to hard magnetic when the Fe content increases up to about 4at% indicating that the magnetic property is related to the metastable phases.

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 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.

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.

Glass formation and magnetic properties of Fe-based metallic glasses fabricated by low-purity industrial materials

Fe-based metallic glasses of(Fe74Nb6B20)100?xCrx(x=1,3,5)with high glass forming ability(GFA)and good magneticproperties were prepared using low-purity raw materials.Increasing Cr content does not significantly change glass transitiontemperature and onset crystallization temperature,while it enhances liquidus temperature.The addition of Cr improves the GFA ofthe(Fe74Nb6B20)100?xCrx glassy alloys compared to that in Cr-free Fe?Nb?B alloys,in which the supercooled liquid region(ΔTx),Trgandγare found to be50?54K,0.526?0.538,and0.367?0.371,respectively.The(Fe74Nb6B20)100?xCrx glassy alloys exhibit excellentsoft magnetic properties with high saturation magnetization of139?161A·m2/kg and low coercivity of30.24?58.9A/m.PresentFe?Nb?B?Cr glassy alloys exhibiting high GFA as well as excellent magnetic properties and low manufacturing cost make themsuitable for magnetic components for engineering application.

3-D Magnetic Sensor Module for Locating and Tracking MEMS Swallowable Capsule Based on Scalar Form of Magnetic Dipole Model

MEMS swallowable capsule is a novel technology in the non-invasive surgery. This technology provides a way to diagnose directly into the deep intestinal where the traditional invasive technology implemented, such as X-Ray, endoscopy. It is a key for us to locate and track the position of a MEMS capsule in clinical applications. To solve this problem, we implemented a magnetic sensor module based on the scalar form of the magnetic dipole model,which was designed with very small size （5.2 ＊ 2. 1 ＊ 1.2 em） and easy to assemble to satisfy the system requirement. Here we discuss in detail the principle of magnetic dipole model, rules of selecting sensor and functions of the module. Some trials are established to test the characteristic of the module. The results of the Cm experiment demonstrates that the module follows the rules of the new magnetic dipole model form.

New Technology “Flotation to Form Agglomerates and Magnetic Separation” Allows Great Breakthrough for World Low-Grade Light Rare Earth Ores

Rare earth resources are relatively scarce worldwide, but their global consumption is increasing year-by-year. At present, China has about 36% of the global rare earth reserves, but provides 90% of the world＇s supply, which has generally met world demand and promoted the development of the world economy. In order to continuously and stably supply rare earths to international markets, the Chinese Government has financially supported the Institute of Multipurpose Utilization of Mineral Resources within the China Geological Survey to study the utilization of low-grade rare earth ores. Following many years of experimental research, the project has developed a new technology entitled ＂Flotation to Form Agglomerates and then Magnetic Separation＂, which will bring a technological revolution to the world＇s light rare earth ore dressing.

Effects of yttrium on the formation and magnetic properties of bulk metallic glassy(Fe,Co)-B-Si-Nb alloys

The bulk metallic glassy （BMG） rods of [（Fe0.5Co0.5）0.72B0.192Si0.048Nb0.04]100-xYx （x=0-6） and [（FexCO1-x）0.72B0.192Si0.048Nb0.04]96Y4 （x=0.5-0.8） were prepared by copper mold casting. The structure, thermal stability, and magnetic properties of the samples were studied by X-ray diffraction （XRD）, differential scanning calorimetry （DSC）, and vibrating sample magnetometer （VSM）. Adding 1 at% to 6at% of yttrium, the bulk glassy alloy rods of [（Fe0.5Co0.5）0.72B0.192Si0.048Nb0.04]100-xYx （x=0-6） with the diameter of 3 mm were not formed, and the sample with 4at% of yttrium showed less crystalline phase than others. When the Fe/Co atomic ratio was between 5：5 and 7：3, the bulk glassy alloy rods of [（Fe1-xCox）0.72B0.192Si0.048Nb0.04]96Y4 （x=0.5-0.8） with the diameter of 2 mm were fabricated. In the （Fe, Co）-B-Si-Nb-Y BMGs, when the Fe content increased, the thermal stability, the supercooled liquid region, and the glass-forming ability （GFA） decreased, but the saturation magnetization （Ms） increased.

A FINITE-ELEMENT ANALYSIS OF ELECTROMAGNETIC SHEET METAL-EXPANSION PROCESS

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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.

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.

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.

Differential Integrals of Curves and Inversion of Magnetic Source Morphology

In this paper, the problem of magnetic source shape determination is simplified into iterative inversion after symbol recognition. Based on the theory of differentiating different forms of magnetic sources by integral magnetic anomaly curves, a unified expression for calculating magnetic fields of different magnetic sources under undulating terrain conditions is given, and the triangular system plate interpretation method is used to identify the magnetic fields of different magnetic sources. The calculus parameter basis for the classification of unknown magnetic source morphology and the method technology for determining the magnetic source spatial morphology are confirmed. The example shows that the application of the calculus triangulation method to the magnetic source morphological system inversion has a good prospect.

Finite element analysis of free expansion of aluminum alloy tube under magnetic pressure

A link between the electromagnetic code, ANSYS/Emag and the structural code, Ls-dyna was developed, and the numerical modeling of electromagnetic forming for aluminum alloy tube expansion was performed by means of them (discharge energy 0.75kJ). A realistic distribution of magnetic pressure was calculated. The calculated values of displacement along the tube axis and versus time are in very good agreement with the measured ones. The maximum strain rate is 1122s -1, which is not large enough to change the constitutive equations of aluminum alloy. With the augment of discharge energy (0.51.0kJ), the relative errors of the maximum deformation increase from 2.93% to 11.4%. Therefore, coupled numerical modeling of the electromagnetic field and the structural field should be performed to investigate the electromagnetic forming with larger deformation.

Singularity analysis of Jeffcott rotor-magnetic bearing with time delays

A Jeffcott rotor-magnetic bearing with time delays is investigated in this paper. Firstly, it is found that the characteristic equation of the system satisfies the conditions of the singularity. Secondly, the center manifold reduction and normal form are employed to study the bifurcation from simple zero and zero-purely imaginary singularities. The results of this paper will help to understand the influence of the time delays in feedback loop on the dynamics of rotor-magnetic bearing system.

Design of FeSiBPCu soft magnetic alloys with good amorphous forming ability and ultra-wide crystallization window

The Fe_(81.3)Si_(4)B_(13–x)PxCu_(1.7) soft magnetic alloys with high Cu and proper P elements addition were synthesized with the aim of ensuring the amorphous forming ability(AFA)while expanding the crystallization window(CW).It is found that the atomic ratio of P/Cu of∼3 is advantageous for AFA whereas a small amount of P addition promotes the precipitation ofα-Fe grains and excessive P addition induces surface crystallization behavior of the present alloys.High Cu concentration can expand the annealing temperature(Ta)window whereas proper P addition effectively expands the annealing time(ta)window.The Fe_(81.3)Si_(4)B_(13-x)PxCu_(1.7) soft magnetic alloy was successfully synthesized with a large Ta window of up to 130°C and ta window of 90 min,which is a breakthrough for nanocrystalline alloys with high saturation magnetization.Microstructure analysis reveals that the ultra-wide CW is related to the unique nucleation mechanism,that is,theα-Fe grains are precipitated attaching to the Cu or CuP clusters and enveloping the Cu clusters,resulting in the high number density ofα-Fe nanocrystals.The ultra-wide CW promises the potential material in flexibly choosing the annealing process according to the performance.

Role of compositional changes on thermal,magnetic,and mechanical properties of Fe-P-C-based amorphous alloys

This work aimed to tune the comprehensive properties of Fe-P-C-based amorphous system through investigating the role of microalloying process on the crystallization behavior,glass forming ability(GFA),soft magnetic features,and mechanical properties.Considering minor addition of elements into the system,it was found that the simultaneous microalloying of Ni and Co leads to the highest GFA,which was due to the optimization of compositional heterogeneity and creation of near-eutectic composition.Moreover,the FeCoNiCuPC amorphous alloy exhibited the best anelastic/viscoplastic behavior under the nanoindentation test,which was owing to the intensified structural fluctuations in the system.However,the improved plasticity by the extra Cu addition comes at the expense of magnetic properties,so that the saturation magnetization of this alloying system is significantly decreased compared to the FeCoPC amorphous alloy with the highest soft magnetic properties.In total,the results indicated that a combination of added elemental constitutes,i.e.,Fe69Co5Ni5Cu1P13C7 composition,provides an optimized state for the comprehensive properties in the alloying system.