Analysis of coil temperature rise in electromagnetic forming with coupled cooling method

Qiu, Li; Deng, Kui; Li, Yantao; Tian, Xi; Xiong, Qi; Peng, Chang; Su, Pan; Huang, Lantao

doi:10.3233/jae-190062

Cited by 18 publications

(10 citation statements)

References 17 publications

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“…Electromagnetic forming (EMF) is an industry technology that utilizes pulsed electromagnetic force to accelerate and deform metal workpieces [1]- [3]. The forming process is conducted in a time range of millisecond with a workpiece forming speed exceeding 300 m/s [4], [5]. Compared with conventional machining, EMF can improve the forming limit of materials [3], [6] and has become one of the recent hot research topics with a main goal of improving its performance [7].…”

Section: Introductionmentioning

confidence: 99%

Electromagnetic Force Distribution and Wall Thickness Reduction of Three-Coil Electromagnetic Tube Bulging With Axial Compression

et al. 2020

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In the conventional electromagnetic tube expansion, tube wall thickness tends to decrease significantly while the workpiece is expanded. This paper is aimed at introducing a new technique using three-coil electromagnetic tube bulging with axial compression as an innovative solution for this issue. To validate the feasibility of the proposed technique and investigate the electromagnetic force distribution along the workpiece, COMSOL software is used to construct a detailed finite element analysis model for the proposed electromagnetic coupling model. Results show that the ratio of the axial and the radial electromagnetic forces increases linearly with the increase of the height and the outer diameter of the top and bottom coils. Furthermore, the tube deformation profile and the wall thickness are compared with two different coil structures. Comparison analysis reveals that for the same axial to radial electromagnetic forces ratio, the effect of prohibiting the wall thickness reduction using different coil structures is quite similar. The new method is expected to have a good potential in enhancing the tube-forming performance. INDEX TERMS Electromagnetic forming, tube bulging, axial electromagnetic force, tube wall thickness.

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Section: Introductionmentioning

confidence: 99%

Electromagnetic Force Distribution and Wall Thickness Reduction of Three-Coil Electromagnetic Tube Bulging With Axial Compression

et al. 2020

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“…To compensate for the insufficient electromagnetic force on workpieces of low conductivity and improve the forming limit, an additional driver of high conductivity between the driving coil and the workpiece is proposed in [12], [13]. While good results have been achieved through the above research attempts, the control of the current EMF method for metal sheet workpieces is not flexible enough and cannot meet the requirements of different processing fields [15]- [20]. Aiming at this point, this paper proposes an EMF method based on the utilization of discretely driven rings.…”

Section: Introductionmentioning

confidence: 99%

Electromagnetic Force Distribution and Forming Performance in Electromagnetic Forming With Discretely Driven Rings

Qiu

Abu-Siada

et al. 2020

IEEE Access

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Electromagnetic forming is a method of high-speed metal workpiece forming technology that uses electromagnetic force pulses generated from the interaction of the magnetic flux density and workpiece induced eddy current. The main challenge of this technology is the control of the eddy current and magnetic flux density to perform various forming processes. This paper is aimed at overcoming this challenge by introducing a new electromagnetic sheet forming method based on discretely driven rings. In this method, a set of discrete conducting rings are placed between the driving coil and the metal workpiece to enhance the shaping process of the workpiece. By changing the number and position of the rings, the induced eddy current can be adjusted, and different electromagnetic force distribution profiles can be realized. COMSOL software is used to develop an electromagnetic field-structure coupling model of the proposed electromagnetic forming method. The characteristics of the electromagnetic force distribution and its effect on the workpiece forming process are analyzed. Results show that the electromagnetic force distribution profile can be controlled by adjusting the rings physical parameters such as diameter, material, and position. The proposed method can effectively improve the performance of the conventional electromagnetic forming technology and has the potential for implementation in wide industry applications.

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“…For example, the weight of the aircraft body is reduced by 5kg, while the effective commercial load can be increased by 50kg when the body is made of lightweight alloy [2]. Similarly, when lightweight alloy material is used in manufacturing cars, the weight is reduced by 10%, and the fuel consumption is reduced by 6% to 8% [3]. However, alloy materials exhibit low room temperature forming plasticity, poor local drawability and they are prone to cracks and possessing large spring back which makes the traditional alloy processing technology not ideal [4][5].…”

Section: Introductionmentioning

confidence: 99%

Parametric Simulation Analysis of the Electromagnetic Force Distribution and Formability of Tube Electromagnetic Bulging Based on Auxiliary Coil

et al. 2020

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Tube electromagnetic bulging has been given much attention due to its superior advantages in the field of light alloy processing. However, the conventional tube electromagnetic bulging process exhibits some critical issues that restrict its wide industrial applications. This includes non-uniform axial deformation and poor forming performance such as wall thickness thinning. This paper proposes a costeffective solution for such issues through simultaneous radial and axial electromagnetic force loading using an auxiliary driving coil. In this regard, the influence of the auxiliary coil geometrical parameters on the electromagnetic force distribution and tube forming performance is investigated using electromagneticstructure coupling model of the bulging process. The robustness of the new proposed method is validated by comparing its electromagnetic force distribution and tube forming performance with the traditional cylindrical coil method, currently used by industry practice. Numerical results show that the introduction of the auxiliary coil may effectively weaken the radial electromagnetic force at the end of the tube and solve the uneven axial deformation issue. Based on the obtained results, the maximum uniform deformation area is increased from 6.9mm to 35.1mm. The tube relative wall thinning issue is reduced and the relative wall thickness reduction of the pipe is found to be 0.01661. The axial electromagnetic force can be further improved by adjusting the geometrical parameters of the coil and the proposed electromagnetic bulging can effectively increase the uniform deformation range of the tube.

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Analysis of coil temperature rise in electromagnetic forming with coupled cooling method

Cited by 18 publications

References 17 publications

Electromagnetic Force Distribution and Wall Thickness Reduction of Three-Coil Electromagnetic Tube Bulging With Axial Compression

Electromagnetic Force Distribution and Wall Thickness Reduction of Three-Coil Electromagnetic Tube Bulging With Axial Compression

Electromagnetic Force Distribution and Forming Performance in Electromagnetic Forming With Discretely Driven Rings

Parametric Simulation Analysis of the Electromagnetic Force Distribution and Formability of Tube Electromagnetic Bulging Based on Auxiliary Coil

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