Material Formability and Coil Design in Electromagnetic Forming |
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Authors: | Sergey F Golovashchenko |
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Affiliation: | (1) Manufacturing & Processes Department, Ford Research & Advanced Engineering Scientific Research Laboratory, 2101 Village Rd, Dearborn, MI 48124, USA |
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Abstract: | Pulsed electromagnetic forming is based on high-voltage discharge of capacitors through a coil. An intense transient magnetic
field is generated in the coil and through interaction with the metal work-piece; pressure in the form of a magnetic pulse
is built up to do the work. Data on formability of two aluminum alloys employed for exterior (6111-T4) and interior (5754)
automotive body panels will be shown. Comparison of traditional Forming Limit Diagrams obtained by stretching of aluminum
sheet with hemispherical punch to the results on formability, where hemispherical punch is replaced by a coil will be provided.
It will be shown that material formability in high-rate forming conditions can significantly depend upon interaction with
the forming die: electromagnetic forming into an open round window provides only slight improvement in formability, while
forming in a V-shape die or into a conical die indicates a significant improvement. An important part of the electromagnetic
forming technology is the design of the coil. The coil failure modes and measures preventing them are discussed.
This article was presented at Materials Science & Technology 2006, Innovations in Metal Forming symposium held October 15-19,
2006 in Cincinnati, OH. |
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Keywords: | aluminum alloy electrical discharge sheet metal stamping |
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