A Uniform Pressure Electromagnetic Actuator for Forming Flat Sheets

Abstract

High velocity electromagnetic forming can lead to better formability along with additional benefits. The spatial distribution of forming pressure in electromagnetic forming can be controlled by the configuration of the actuator. A new type of actuator is discussed which gives a uniform pressure distribution in forming. It also provides a mechanically robust design and has a high efficiency for flat sheet forming. A simplified analysis of the actuator is presented that helps in the design of the system. Examples of uses of the actuator are then presented, specifically with regards to forming shapes and surface embossing. Some practical challenges in the design of the actuator are also addressed. This paper emphasizes the approaches and engineering calculations required to effectively use this actuator.

Simplified Mathematical Modeling for an Electromagnetic Forming System with Flat Spiral Coil as Actuator

“…The pitch of the coil actuator has influence in this uniformity of the magnetic field at the same time it is limited by the mechanical rigidity and electrical insulation of the actuator coil (Kamal, 2005).…”

“…The calculations of the electromagnetic problem use a method based on discretization of the metal sheet in a number of circular elementary conductors for axisymmetric configuration. The transient electromagnetic problem can be separated in a RLC primary circuit coupled with secondary RL circuit (Kamal, 2005;Shang, 2006). The discharge of the capacitor in the primary circuit can be written in ordinary differential equations:…”

“…These methods include techniques such as explosive forming and electromagnetic forming. These techniques are distinct from most other metal forming methods in that the workpiece is accelerated to a high velocity by the chemical, mechanical or electrical force, and the kinetic energy of the workpiece is significant (Kamal, 2005).…”

“…Looking at the current technological possibilities there are a number of methods for high velocity forming mainly based on the source of energy used for obtaining high velocities. The common ones are (Kamal, 2005):…”

Plastic Deformation Zone in Electromagnetic Cutting

“…In the conditions of limited natural resources, increasing natural environment pollution, the necessity of saving energy and the consequent stringent legal requirements (recycling), light construction materials become increasingly important. Moreover, companies introduce state-of-the-art technologies to further enhance their products, which in turn leads to even more innovative solutions [1,2]. For this reason in the highly innovative automotive industry light construction material are used on an increasingly large scale.…”