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Article history: Impulse electromagnetic forming (IEMF) is an effective and powerful technique widely used
Received 13 March 2007 for joining and shaping metals and eld-shaper is a main part of the electromagnetic form-
Received in revised form 6 May 2008 ing which has important effect on the distribution of magnetic eld. In this technique, a
Accepted 11 May 2008 metal work-piece is pushed to a die and formed by a pressure created using an intensive,
transient magnetic eld. This magnetic eld is produced by passing a pulse of electric cur-
rent through a forming coil in a pulsed power circuit. The produced transient magnetic eld
Keywords: induces eddy currents in the surface of work-piece. Induced eddy currents in work-piece
Field-shaper produce a magnetic eld with reverse direction of initial magnetic eld; this results in a
Electromagnetic forming mutual repulsion between coil and work-piece and in this way the work-piece is thrown
Magnetic pressure toward the die. In this process created magnetic forces applied to work-piece are much like
Numerical simulation uniform, but in real applications, some regions of a work-piece have to be more deformed
IEMF and therefore a much greater pressure has to be applied to these regions. The task of concen-
tration of magnetic forces to some desired regions can be accomplished using eld-shapers.
Yu et al. [Yu, H., Li, C., Zhao, Z., Li, Z., 2005. Effects of eld-shaper on magnetic pressure in
electromagnetic forming. J. Mater. Process. Technol. 168, 245249] have recently shown the
effect of eld-shaper on the distribution of the magnetic elds in electromagnetic forming,
but because of the nature of 2D simulations some edge effects in real geometries could not
be taken into consideration. In this paper, a 3D simulation using the FEA software MAXWELL
has been applied to study the magnetic eld distribution during an impulse electromagnetic
forming process. Comparison of the 3D and 2D simulation results indicates that the maxi-
mum magnetic elds achieved in front of nodules of the eld-shaper are about 15% stronger
than those expected by 2D simulations.
By changing the geometry of the eld-shaper, the inuence of the shape of the eld-shaper
on the distribution of the applied forces on the work-piece has been studied. Based on these
simulations, some simple guidelines to design the eld-shaper have been derived.
2008 Elsevier B.V. All rights reserved.
1. Introduction failure in low ductility materials due to strain rate and inertial
stabilization of material failure modes. Impulse electromag-
High-rate forming processes such as impulse electromagnetic netic forming is a powerful and effective high-rate forming
forming (IEMF) can promote signicant increases in strain to technique with a number of advantages such as high clean-
Corresponding author at: School of Electrical and Computer Engineering, University of Tehran, North Karegar Avenue, P.O. Box:
14395/515, IR-14395 Tehran, Iran. Tel.: +98 21 88011247; fax: +98 21 88027766.
E-mail addresses: m.bahmani@ece.ut.ac.ir (M.A. Bahmani), kniayesh@ut.ac.ir (K. Niayesh).
0924-0136/$ see front matter 2008 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2008.05.024
2296 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 9 ( 2 0 0 9 ) 22952301
1
= (3)
f
0 2
p= H (4)
2
Fig. 3 Mesh operation in a cross-section. is solved only within the work-piece, the radial coordinate is
always nonzero in the considered conguration and the Eq. (6)
is well dened.
This is the response of a lossy LC resonance circuit. As it will Fig. 4 shows typical displacement and velocity increase of
be seen in the following sections, the magnetic eld distribu- the work-piece during the electromagnetic forming process.
tion is proportional to the current amplitude, and therefore it Due to the displacement and deformation of the work-piece,
is possible to use the results of these simulations to predict the the air gaps in the equivalent magnetic circuit of the congu-
magnetic eld distributions with different current amplitudes. ration considered here increase with time. This leads to lower
Moreover, it is assumed that the work-coil is made of cop- magnetic ux densities compared with the case where the
per, the eld-shaper of copperberyllium and the work-piece displacement of the work-piece is not considered.
of aluminum. The gas lling the region between solids is air.
3.1.1. Boundary conditions
3.1. Model and boundary conditions In this paper, two types of boundary conditions are used:
In Fig. 3, a cross-section of a typical mesh generated during the 1. Natural boundaries: they are assigned to the surfaces
simulation is shown. This consists of 1037 elements for coil, between objects. The natural boundary condition reects
36,289 elements for eld-shaper, 11,651 elements for work- the particular local form of Maxwells equations at the
piece and 61,208 elements for air region. In solids, tetrahedral interface between objects where there is a sudden change
cells and in air region, hexahedral cells have been used as in the material properties and the normal component of B
elements. The hexahedral grid system has been connected is continuous (Manual of the FEA Software Maxwell, 2006).
through Pyramid cells to the tetrahedral grid system at inter- 2. Neumann boundaries: they are assigned to the outside
faces. The quadrilateral cell face of the hexahedral cell system edges of the problem region. The homogeneous Neumann
forms the base of ve sided pyramid cell. The four triangular boundary condition species that the normal component
sides of the pyramid cell are used as boundaries for the tetra- of the H eld is zero (Manual of the FEA Software Maxwell,
hedral grid system, so the interface between the hexahedral 2006).
and tetrahedral grid system is a true interface and the arbitrary
interface feature is not needed. 3.2. Simulation results
During the electromagnetic forming process, the work-
piece is deformed and accelerated towards the die. The change Fig. 5 shows the magnetic ux density distribution in the
in the geometry resulted during the mechanical deformation whole region without the eld-shaper. In Fig. 6, for the same
of the work-piece, has an impact on the magnetic ux den- geometry of the work-coil and work-piece the magnetic eld
sity distribution. To be able to take this phenomenon into distribution with eld-shaper is shown.
account, the deformation and displacement of the work-piece As it can be seen, the magnetic ux density near the nod-
is simulated using the equivalent surface forces method as ule of eld-shaper has much greater values compared to the
demonstrated (Motoasca, 2003). For this purpose, the following situation without eld-shaper. To be able to have a quantita-
equation has to be solved: tive comparison between these two situations, the magnetic
ux density along the Z-axis near the work-piece is shown
1 1 1 in Fig. 7. The results indicate that the magnetic ux densities
r2 ur + r ur 2 ur 2 r2 ur = 0 (6)
r r CP in the desired region (here on the nodules) are increased by
4050%. So, according to Eq. (4), the magnetic pressure with
where r is the radial coordinate, ur is the radial displacement of eld-shaper is more than two times stronger than the situa-
the work-piece and CP is the compressional or p-wave speed tion without eld-shaper. In other regions, the magnetic ux
that is typically between 1000 and 14,000 m/s. As the Eq. (6) density is decreased inserting the eld-shaper.
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 9 ( 2 0 0 9 ) 22952301 2299
references
Fig. 13 Enhancement factor of B for various eld-shapers
with three different radius of IEMF system.
Batygin, Y.V., Daehn, G.S., 1999. The Pulse Magnetic Fields for
Progressive Technologies. Kharkov, Columbus.
would be possible to determine the necessary current ampli- Davis, J.R., Semiatin, S.L., 1993, ASM Metal Forming Handbook, p.
tude to achieve the desired magnetic pressure at the desired 14.
region. Yu, H., Li, C., Zhao, Z., Li, Z., 2005. Effects of eld-shaper on
magnetic pressure in electromagnetic forming. J. Mater.
Process. Technol. 168, 245249.
4. Conclusions Motoasca, T.E., 2003. Electrodynamics in Deformable Solids for
Electromagnetic Forming, Ridderprint Offsetdrukkerij B.V.
Impulse electromagnetic forming (IEMF) is a powerful and Manual of the FEA Software Maxwell, V. 11.1, 2006.
Oliveira, D.A., 2002. Electromagnetic forming of aluminium alloy
effective high-rate forming technique with a number of advan-
sheet experiment and model. Masters Thesis, Department of
tages such as high cleanness, cost-efciency, productivity. To
Mechanical Engineering University of Waterloo, Ontario,
be able to apply the desired pressure to different regions of Canada.
the work-piece to achieve the ideal forming, in this technique Oliveira, D.A., Warwick, M.J., 2003. Electromagnetic forming of
a so-called eld-shaper is used to transfer the stored electrical aluminium alloy sheet. J. Phys. 110, 293298.
energy to the desired points. In this process, the distribution of