Agile manufacturing of a micro-embossed case by a two-step electromagnetic forming process

Kamal, Manish; Shang, Jianhui; Cheng, Victor; Hatkevich, Steve; Daehn, Glenn S.

doi:10.1016/j.jmatprotec.2007.03.114

Cited by 85 publications

(25 citation statements)

References 4 publications

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“…The sheets thickness s 0 is varied to investigate the influence of sheet thickness and skin depth. Due to embossing experiments a clearance d c between the sheet and the tool has to be defined to accelerate the sheet to a velocity of 200 m/s enhancing the embossing result due to its kinetic energy [3,4,9]. For this the effective force is measured varying d c .…”

Section: Set Upmentioning

confidence: 99%

“…5). A higher energy leads to a higher current pulse which 11002-p. 4 ICNFT 2015 directly influences the strength of the magnetic field and the induced eddy currents. According to Eq.…”

Section: Parameter Studymentioning

confidence: 99%

“…Hence, electromagnetic forming is widely investigated for sheet metals and cylindrical workpieces with a thickness s 0 of more than 1 mm [2]. Though electromagnetic forming is introduced to micro forming in special regard to the advantages like higher plasticity and simple tools without narrow tolerances [3][4][5]. The challenge of electromagnetic forming thin sheet metals is to compensate the decrease of body forces with decreasing sheet volume.…”

Section: Introductionmentioning

confidence: 99%

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Effective electromagnetic forces in thin sheet metal specimen

Langstädtler

Schenck

Kuhfuß

2015

MATEC Web of Conferences

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Abstract. Electromagnetic forming is mainly investigated for the macro world as the body forces in this high speed process are decreasing with the volume of the specimen. For micro metal sheets different effects are observed which make an analysis of the acting forces more difficult. Hence, the validity of process simulations for electromagnetic forming is still limited. In this research the effective electromagnetic force on thin EN AW-1050A (Al99.5) sheet metals is investigated by varying the loading energy E C , the ration s R between sheet thickness and skin depth, the sheets width b and the distance d c between passive tool and sheet metal. BackgroundElectromagnetic forming is a high speed forming method where one part of the tool is replaced by a strong pulsed electromagnetic field. In the process a high current peak I max in a tool coil induces eddy currents in an electrical conductive workpiece and accelerates it by repulsive body forces F L (Lorentz' forces) (see Fig. 1).The current peak is generated by a LC-resonator. The process energy E C of the capacitor is influenced by its capacity C and the loading voltage U 0 , Eq. (1).( 1 )According to the skin effect the induced eddy currents are limited to the skin depth . Depending on the coil, the workpiece can be shaped axis-symmetrically or planar and be used for different manufacturing processes like forming, embossing, cutting and joining. A technical advantage of electromagnetic forming is the high deformation rate (typical 2500 1/s [1]) which leads to higher plasticity. By replacing one part of the tool by contactless working forces there are no clearances between tool parts and the risk of abrasion decreases. The economical advantages of electromagnetic forming are the short cycle times and the lower tool costs. For electromagnetic forming the body forces f are depending on the current density J in the sheet and the magnetic field density B, Eq. (2).

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Section: Set Upmentioning

confidence: 99%

“…5). A higher energy leads to a higher current pulse which 11002-p. 4 ICNFT 2015 directly influences the strength of the magnetic field and the induced eddy currents. According to Eq.…”

Section: Parameter Studymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Effective electromagnetic forces in thin sheet metal specimen

Langstädtler

Schenck

Kuhfuß

2015

MATEC Web of Conferences

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“…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.…”

Section: Introductionmentioning

confidence: 99%

Plastic Deformation Zone in Electromagnetic Cutting

Zimniak

2017

Archives of Metallurgy and Materials

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PLASTIC DEFORMATION ZONE IN ELECTROMAGNETIC CUTTINGThis paper presents the application of the electromagnetic field as a tool for metal sheet cutting. The experiments showed that one can easily adapt the conventional cutting equipment to the electromagnetic cutting technology and thereby eliminate the mechanical work of the punch and the press. Two methods exploiting the electromagnetic field as the tool for cutting sheet metal were used. In one of the methods the cutting element was a die while in the other method a punch was used for cutting. Owing to the high quality surface of the cut obtained by each of the methods the cutting process does not entail additional costs for removing burrs. The shape of the surface of the cut is different than the one obtained by traditional blanking -no zones characteristic of the latter are present here. In the case of both materials, the rollover of the sheet surface is much larger and longer than in the conventional method. In comparison with the conventional method, the electromagnetic machining technology ensures high quality of the surface of the cut and can be successfully used in the industry.

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“…Up to now, EMF has been used for sheet/tube forming, joining, welding, cutting, and the calibration of parts. Kamal et al (2007) utilized electromagnetic forces in a two-step method to make a decent phone face. Jäger et al (2011) developed a novel process chain by integrating the aluminum extrusion and an EMF compression process to locally reduce the cross-section of the workpiece to meet industry requirements to some extent.…”

Section: Introductionmentioning

confidence: 99%

Large-scale sheet deformation process by electromagnetic incremental forming combined with stretch forming

Cui

et al. 2016

Journal of Materials Processing Technology

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Agile manufacturing of a micro-embossed case by a two-step electromagnetic forming process

Cited by 85 publications

References 4 publications

Effective electromagnetic forces in thin sheet metal specimen

Effective electromagnetic forces in thin sheet metal specimen

Plastic Deformation Zone in Electromagnetic Cutting

Large-scale sheet deformation process by electromagnetic incremental forming combined with stretch forming

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