电磁胀形管坯所受磁压力的瞬态分布

管坯所受磁压力的准确求解是电磁成形变形分析,优化成形系统工艺参数的基础.通过ANSYS/EMAG软件,用远场单元来说明磁场在远场区间的耗散问题,对电磁胀形时作用在管坯上的磁压力进行准确计算.在线圈长度一定的条件下,讨论了管坯尺寸对磁压力瞬态分布和磁场扩散的影响,并根据管坯端部径向磁压力和中部径向磁压力的比值,提出以磁压力分布不均匀系数来反映磁场不均匀分布的程度.计算结果表明:当管坯和线圈的相对长度大于1时,管坯上与线圈等高处承受轴向拉应力,磁场扩散现象不严重;当相对长度小于0.92时,管坯端部承受轴向压应力,磁场扩散现象严重,相对长度0.92时为电磁胀形均匀成形的条件.     

高温合金电磁软接触近净成形定向凝固研究

传统高温合金叶片类铸件制备过程中,熔体长时间受到陶瓷模壳材料的污染,性能难以提高,借助于电磁软接触成形技术中的电磁压力使高温合金熔体呈半悬浮状态,减少了熔体与磁模结晶器的接触面积和时间,提高了合金熔炼和成形的纯净度,同时将该技术和定向凝固技术相结合开发了一种实现高温合金复杂形状电磁软接触成形定向凝固的工艺,并探讨了该工艺下3种结晶器材料（陶瓷、磁模和石墨）中磁感应强度的分布规律,结果表明,石墨套高度对磁模结晶器磁感应强度的大小和分布以及熔体温度场有很大影响。通过调整上下线圈功率和抽拉速度等工艺参数成功地制备了大小两种近叶片形状的高温合金电磁软接触成形的定向凝固样件。．     

利用高速振动降低零件回弹及蒙皮件制造——电磁成形技术的新应用

目的 为了解决传统大型蒙皮成形需要大型装备及零件回弹大的问题,提出带弹性垫的蒙皮件电磁渐进成形新方法.方法 通过电磁线圈放电,材料在磁压力和弹性垫的反弹力作用下出现高速振动,消除零件回弹.采用ANSYS和ABAQUS有限元分析软件分别进行电磁场和结构场模拟,分析有无弹性垫、线圈结构和放电位置对蒙皮成形质量的影响规律.结果 在无弹性垫的条件下对板料进行冲击,板料上的塑性应变几乎没有变化.如果采用螺旋方形线圈和带弹性垫的成形工艺,虽然板料上的塑性应变增加,但是线圈正对板料区域出现1.5 mm的鼓包.采用电磁屏蔽方法调整板料上的电磁力分布和材料流动,当线圈在6个位置多次放电后,板料回弹明显减低,并且零件表面光滑.结论 在模拟得到的最佳工艺参数下,建立了实验装置,实验结果与模拟一致.     

板料电磁成形磁场力分布研究

为研究平板电磁成形中板料上磁场力的分布规律,基于 Ansys 软件建立了 3 D 电磁场有限元模型,分析了在一定放电脉冲作用下,当板料的平面尺寸小于或等于线圈的几何尺寸时,板料上感应电流和磁场力的分布规律。 结果表明,板料的几何尺寸小于或等于对应线圈尺寸会影响板料上感应电流和磁场力的分布,其中圆形线圈对称放置影响最大,矩形线圈单边放置影响较小,匀压力线圈影响最小。     

电磁成形放电频率对板料变形的影响

目的研究电磁成形放电频率对板料变形的影响规律。方法以商用有限元软件ANSYS为平台,建立板料电磁成形有限元模型。通过数值模拟方法,研究不同厚度的1040铝合金板在不同放电频率下的变形过程,得到不同板厚对应的最优放电频率。对比板料自由胀形试验结果,验证数值模拟的可靠性。结果放电频率对线圈放电电流、板料内电流分布、磁场力分布以及变形影响较大,并且存在最优放电频率使得板料的变形量最大。结论最优相对放电频率随着板厚的增加而减小,其变化规律呈幂指数函数变化。     

管件电磁成形数值模拟方法及缩径变形分析

随着电磁成形工艺应用的发展,需要强有力的数值模拟方法来预测成形过程,并用来指导成形系统设计.归纳了现有的电磁成形模拟方法及各自的特点,讨论了模拟中存在的问题和面临的挑战.应用FEM软件ANSYS对铝合金管件电磁缩径成形进行了数值模拟,研究了管件均匀缩径变形规律.变形管坯轮廓验证了电磁缩径成形的模拟结果.     

铝合金双曲率薄壁件电磁渐进辅助拉伸成形工艺方案设计与开发

目的 针对铝合金双曲率薄壁件传统拉伸成形工艺成形均匀性差的问题,提出一种采用电磁渐进辅助拉伸成形的高精度成形工艺。方法 设计电磁渐进辅助拉伸成形工艺方案,基于有限元仿真软件LS-DYNA R13.0,建立拉伸成形和电磁成形有限元模型。通过数值仿真研究线圈移动路径和放电电压组合对成形质量的影响以及薄壁件的整体贴模成形过程和等效塑性应变。结果 与单程放电相比,双程放电能够大幅度提高板材变形均匀性。与以中间值电压连续放电以及先大电压后小电压的放电电压组合相比,在先小电压后大电压的放电电压组合下,板材的成形质量更高。选择线圈双程顺序移动路径和7 kV-10 kV放电电压组合,通过10次拉伸和9层54次放电,得到了减薄率仅为3%的贴模性良好的双曲率薄壁件。变形量基本呈现随着放电层数的增加而不断降低的趋势。电磁放电仅扩展更大的塑性应变区域,不改变已贴模区板材的塑性应变值。结论 与拉伸成形相比,电磁渐进辅助拉伸成形工艺有效提高了板材的塑性变形程度并极大控制了回弹的发生。     

管件长度对电磁成形线圈放电电流的影响

为研究电磁成形过程线圈放电电流的变化规律,在放电回路分析的基础上,采用试验分析与代数解析相结合的方法研究了管件长度对线圈放电电流的影响.试验结果表明:随着管件长度的增加,线圈放电电流的幅值和频率均增加.通过解析方法定性分析管件长度对线圈放电电流的影响,其结果与试验结果一致.管件长度不同时,放电回路的等效电感不同,管件长度与等效电感成反比.将管件和成形线圈等效为圆柱线圈可定性分析电磁成形系统的电感和互感.     

大口径铝合金波纹管电磁胀形数值模拟

目的研究大口径铝合金波纹管电磁成形过程及工艺参数对成形效果的影响规律。方法针对波纹管现有制造工艺——压弯和焊接复合成形存在压痕严重、焊缝多和可靠性不高等问题,提出采用电磁成形波纹管的方法,并基于ANSYS建立了波纹管电磁胀形的三维有限元分析模型。结果揭示了波纹管电磁胀形过程中的应力应变分布规律,发现波纹区域和过渡圆角区域是应力和应变集中区。采用单因素实验方法,获得了放电电压和线圈匝数对成形质量的影响规律。结论在波纹管电磁胀形过程中,波纹区域的应力和应变均呈圆环带状分布,波纹管的壁厚在波纹的波峰处达到最小,最大减薄率为10.67%。放电电压和线圈匝数都存在一个最佳值。放电电压过小时,成形不足,放电电压过大时,工件高速碰撞模具,引起较大反弹,导致最终贴模性较差;线圈匝数也对成形质量有一定的影响,在本次模拟实验中,11匝线圈作用下的工件贴模性最佳。     

电磁成形中矩形截面板件所受电磁压力的三维有限元分析

通过三维Aφ-A法计算了电磁约束成形过程中磁感应强度、涡流密度和集肤层的分布;对具有不同曲率半径倒角的矩形截面样件所受电磁压力的分析发现:磁感应强度在角部最大,涡流集肤层在角部变厚;电磁压力总体分布在角部最大,但当曲率半径在接近或小于集肤层厚度时,该处电磁压力会形成峰谷形分布.     

Magnetic field enhancement in electromagnetic forming systems using anisotropic materials

Electromagnetic Forming (EMF) is a type of high rate forming which exploits pulsed power techniques to create high intensive pulsed magnetic fields to rapidly reshape metal parts. This technique is sometimes called magnetic pulse forming. In this technique, a metal work-piece is pushed to a die and formed by a pressure created using an intensive, transient magnetic field. This magnetic field is produced by passing a pulse of electric current through a forming coil in a pulsed power circuit. Application of field shapers has been proposed to enhance the magnetic fields and consequently to increase the applied magnetic pressure at some desired regions. In this paper, 3D Finite element simulations have been applied to study the magnetic field distribution during an electromagnetic forming process with anisotropic material. Anisotropic magnetic material is described using a permeability tensor. Elements of this tensor are obtained from different magnetization curves dependent on the direction of the magnetic field. It has been shown that application of anisotropic materials with appropriate lamination directions can result in an enhancement of the magnetic field at desired points as well as in better overall efficiencies.     

Two Dimension Finite Element Simulations on the Electromagnetic Containment in Twin-Roll Strip Casting

Distribution of magnetic field and electromagnetic force in twin-roll casting of steels was studied by the metod of numerical simulation in this paper,Two-dimension finite element model ,which includes the regions of melt ,stainless collar ,coil and magnetic core ,has been constructed,By solving magnetic vector potential formulations of quasi-static electromagnetic field,distribution of magnetic flux density and magnetic force at different molten heigh is determined,Calculated results showed that intensity of the distribution of magnetic flux density increased linearly with the increased coil current ;and the magnetic force in the melt increased as a quadratic cure with creased coil current ,More attention was given to the distribution of eddy current and magnetic force in the melt ,the confine effect at different molten height was also discussed.     

Electromagnetic Analysis of the ITER Upper VS Coil

In order to control the plasma vertical stability of ITER, a novel magnet is developed, that is the vertical stability coil. The coil is located in the vacuum vessel and its safe operation is very important for ITER’s reliable working. During the normal operation, the coil should bear the electromagnetic force caused by the external superconducting magnet and plasma current. The electromagnetic load is one of the important factors to affect the lifetime of the VS coil. Therefore, it is necessary to calculate the magnetic field and evaluate the structural reliability under the electromagnetic load. In this paper, the current at the time “end of burn” was selected to perform the electromagnetic calculation. Based on the Maxwell equation, the magnetic field on the cross section of the upper VS coil was computed and the maximum electromagnetic force corresponding to the magnetic field was also presented. In order to verify the current design model, the finite element model was created by use of ANSYS. The Tresca stress was extracted and classified based on analytical design. The peak stress was compared with the ASME criteria. The analysis has verified the physical model from the perspective of electromagnetic load, and it will offer a guidance for the future optimization.     

新型线圈加载的管件电磁胀形电磁力及成形性分析

为了解决传统线圈管件电磁胀形轴向变形不均匀的问题,提出了新型线圈管件电磁胀形方法。首先在COMSOL软件中构造管件电磁胀形二维轴对称电磁-结构耦合模型,从轴向磁通密度、径向电磁力和变形轮廓三个方面,将新型线圈与传统线圈电磁胀形进行对比。结果显示,采用该线圈,可为管件提供凹形分布的径向电磁力,即在管件端部施加较大的径向电磁力,且中部的电磁力满足管件胀形需求,使得轴向变形均匀性提高了2.3倍。显然这种方法能够有效克服传统管件电磁胀形中存在的轴向变形不均匀问题,推动了电磁成形技术在工业的应用。      

一种便捷的新型矩形偏转线圈的设计方法

针对新型矩形偏转线圈的设计提出了一种简单新颖的设计方法。该方法不仅可以避免复杂的三维电磁场计算和优化,而且还可以利用现有的旋转对称偏转线圈的计算结果,因此可节省大量的时间。此外,该方法不仅可用于非旋转对称矩形线圈的设计,还可用于其它的电磁场问题。文中采用一简单的偏转线圈结构模型,从数值计算和实验验证两方面证明了该方法的正确性和可行性。     

Analysis of a novel laminated coil using eddy currents for AC highmagnetic field

The analysis and performance of an eddy current type laminated coil for a high AC magnetic fields are described. It is usually difficult to obtain a high AC magnetic field using an air-gap coil because of eddy currents. The present coil circumvents this limitation by making use of the magnetic shielding effect of eddy currents. Two different realizations of the coil are proposed to provide design flexibility. The field distributions are analyzed by the two-dimensional finite-element method. The coils can also be applied to an induction electromagnetic pump