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Electromagnetic driven forming utilizing a metal ring for controlling shapes of sheet metals

Zhang Wang, Zhu Xinhui, Du Limeng, Sun Yuxuan, Cao Quanliang, Han Xiaotao, Li Liang, Ouyang Shaowei, Qiu Li

Archives of Civil and Mechanical Engineering

2025

Vol. 25, no. 1

art. no. e4, 2025

Electromagnetic forming (EMF) has unique advantages in processing metallic materials owing to the high-strain effect. However, it possesses poor shape-control ability for workpieces and is not suitable for forming materials with low conductivity. To address this, an electromagnetic-driven forming method with a metal driven ring is proposed to achieve Lorentz force transforming and shape control of the workpiece. The effectiveness of this method and ring configurations on the deformation behavior of AA1060-H24 aluminum alloy sheets, along with the forming mechanism, have been thoroughly investigated in combination with experiments and simulations. Results demonstrate that the introduction of the driven ring can adjust the Lorentz force generated on the sheet, resulting in a flat-topped profile with a uniform deformation ratio of 0.62, which increases by 100% compared to that without a driven ring. Meanwhile, it is discovered that the uniform deformed area, forming shapes, and targeted deformation areas can be controlled by regulating the ring configurations, which indicates that the proposed method possesses good adaptability and flexibility in shape control. Moreover, it has also been validated and applied in forming low-conductivity titanium sheets, which can be deformed into a flat-topped shape. This work provides an effective approach for shape control by aggregating the Lorentz force on the driven ring, which is essential for broadening the scope of EMF technology within the domain of sheet metal processing.

Investigation of electromagnetic punching process with adjustable collision velocity for ultra‑thin titanium sheet

Huang Yifan, Wu Zelin, Dong Pengxin, Liu Runze, Chen Yao, Han Xiaotao

Archives of Civil and Mechanical Engineering

2023

Vol. 23, no. 4

art. e263, 1--17

Electromagnetic punching (EMP) is a new type of high-speed punching technology. In the existing EMP method, the blank has no initial loading velocity, so the punching force can only be increased by boosting the discharge energy, which greatly reduces the energy utilization and limits its application in high-strength thin sheet punching. To this end, this paper proposes and validates an EMP method with adjustable initial collision velocity based on the inner-field uniform pressure actuator (UPA) for manufacturing punched parts of TA1 pure titanium foil sheet. The results show that with the increase of collision velocity, the punchable aperture range expands, the dimensional accuracy and section quality of punched parts are significantly improved, and a punchable window is established. In addition, based on the dynamic material constitutive and fracture model, the electromagnetic-structural field simulation model of EMP is established. The analysis shows that the formation of the fracture section is the result of the combined effect of tensile stress and shear stress, and the increase of the collision velocity improves the section quality. Finally, a 100 μm thick titanium sheet with a hole diameter of 2–16 mm and a maximum dimension accuracy of less than 10 μm was successfully punched.