Physical principles of electromagnetic forming process: a constitutive finite element model

Mamalis, A.G.; Manolakos, D.E.; Kladas, A.; Koumoutsos, A. K.

doi:10.1016/j.jmatprotec.2004.07.039

Cited by 28 publications

(19 citation statements)

References 4 publications

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“…Final deformation of the tube has no significant effect of transient magnetic field. Total deformation is achieved at 1/4th time of total cycle time (Mamalis et al, 2005). Here, as the total time period is 88 µs so ideally the maximum deformation should occur at 22 µs.…”

Section: Displacementmentioning

confidence: 99%

Finite element analysis of effect of process parameters on electromagnetic free expansion of aluminium tube

Patel

Ghatule

Kore

2017

IJMPT

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Abstract:The paper focuses on the study of expansion velocity and effective plastic strain with numerical analysis of electromagnetic tube expansion. Effects of process parameters on EM free expansion of tube are discussed in detail. FEM results are obtained through 3D simulations with the help of EM module in LS-DYNA TM in which finite element method (FEM) for conductor and boundary element method (BEM) for surrounding air is implemented. FEM and BEM results are obtained from simulation and compared with available experimental data in the published literature. Increase in capacitance to increase energy is not favourable for electromagnetic forming. Variation in voltage to increase energy is suitable for electromagnetic forming.

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Section: Displacementmentioning

confidence: 99%

Finite element analysis of effect of process parameters on electromagnetic free expansion of aluminium tube

Patel

Ghatule

Kore

2017

IJMPT

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“…Les bases pour la modélisation de l'impulsion magnétique sont présentées dans leurs travaux ainsi que dans les travaux de Mamalis et al [Mamalis et al 2005] . Etant donné l'invariance par rotation autour de l'axe de la bobine, un modèle axi-symétrique est retenu.…”

Section: Etudes Numériques Sur Le Formage Par Impulsion Magnétiqueunclassified

Étude numérique du soudage par impulsion magnétique /

Guglielmetti¹

2012

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Cette thèse traite de la simulation numérique du processus de soudage par impulsion magné-tique. Le but est de pouvoir prédire la soudabilité d'un essai. Une première partie permet de se familiariser avec le procédé et une recherche bibliographique est présentée. Le soudage par explosion sert de comparatif pour dégager les critères de soudabilité, tandis que les études numériques sur le formage par impulsion magnétique permettent une première approche de la modélisation par le couplage séquentiel. La seconde section traite de la simulation électromagnétique dans ANSYS, simulation qui part d'un courant imposé dans une bobine pour arriver au calcul des forces de Lorentz qui vont propulser le tube extérieur sur le tube intérieur, tout deux placés de façon concentrique dans la bobine. Le modèle développé est vérifié et une étude de sensibilité des paramètres matériau et de dispositif est menée. Dans la troisième partie le modèle mécanique est développé dans ABAQUS/Explicit et les différentes opportunités de couplage ainsi que les nombreuses difficultés présentées. Par un couplage séquentiel, un outil de simulation du formage a été codé et par couplage séquentiello-faible, l'outil de simulation du soudage. Enfin une dernière partie permet d'exploiter l'outil numérique pour optimiser les essais ; l'analyse est faite selon 3 critères : vitesse d'impact, vitesse de collision et angle d'impact. Dans un premier temps, une étude de sensibilité rend compte des tendances des influences des divers paramètres ; ensuite un cas concret fictif est pris et une méthode est mise en place pour optimiser les paramètres que l'utilisateur choisira afin de parvenie au meilleur cordon de soudure. Magnetic Pulse Welding numerical study SummaryThis thesis deals with numerical simulation of magnetic pulse welding. The goal is to be able to predict if welding will occur or not. In a first part, one gains knowledge with the process and a state of art is presented. Explosive welding is used for comparison to bring out the welding criteria while numerical study on magnetic pulse forming gives a first approach of modeling with a sequential coupling. The second section deals with electromagnetic modeling with ANSYS. This simulation starts with an imposed current in a coil and ends with the computation of the Lorentz force that will propel the exterior tube on the interior one. Both tubes are collinearly put in the coil. The developed model is validated and a sensibility study of the material and device is made. In a third part, the mechanical model is developed with ABAQUS/Explicit and the various opportunities and numerous difficulties presented. A tool for simulation of the forming with sequential coupling and a tool for simulation of the welding with sequentiallo-weak coupling is proposed. Finally, in the last part, the numerical tool is used to optimize test. Analysis is done by 3 criteria : impact speed, collision speed and collision angle. First, the trend of the parameters influence is examined. Then, an imaginary concreted example is used ...

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“…A.G. Mamalis [10] presented a 3D loose coupled model based on ANSYS Multiphysics to simulate the free compression of aluminum tubes with a solenoid coil. And a more accurate sequential coupled algorithm was proposed by Yu Haiping [11], in which ANSYS/EMAG and ANSYS/MECHANICAL Codes are employed to update the tube geometry and Lorentz forces as loading proceeds, and the mechanical displacement of the AA3003 aluminum tubes is more efficiently treated in this way and the final tube profile of simulation agrees well with that of experiment.…”

Section: Introductionmentioning

confidence: 99%

Numerical modeling and experimental analysis of deformation behaviors during electromagnetic flaring process of thin-walled copper tubes

Luo¹,

Huang²,

Liu³

et al. 2013

AIP Conference Proceedings

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Optimization of an asymmetric thin-walled tube in rotary draw bending process AIP Conf.Abstract. To control thinning is a challenge in traditional flaring process of thin-walled tubes. Electromagnetic forming provides a new way to expand the tubes end with uniform wall thickness, as it can produce a uniform distribution of magnetic force on tubes and easily form by one step based on adjusting the discharge parameters. In this paper, a 3D asymmetric finite element model of electromagnetic flaring of thin-walled copper tubes based on the magnetic vector potential is developed for calculating magnetic field and magnetic forces, and Newmark integration method is used to calculate the dynamic plastic deformation of tubes in the mechanical model. A sequential-coupled simulation approach is developed to analyze the deformation behaviors and the influences of different discharge parameters on deformation behaviors for electromagnetic tube flaring. The deformation height and thinning rate of thin-walled copper tubes show a positive correlation with the charge voltage and capacitance, and deformation zone maintains uniform thickness resulting in smaller thinning rate so as to reduce the trend of crack. Subsequently, some experiments are used to verify the simulation results. A comparison of simulation results and experimental results for final tubes shows a good agreement, and the measured hardness of deformation zone significantly improved after electromagnetic tube flaring.

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Physical principles of electromagnetic forming process: a constitutive finite element model

Cited by 28 publications

References 4 publications

Finite element analysis of effect of process parameters on electromagnetic free expansion of aluminium tube

Finite element analysis of effect of process parameters on electromagnetic free expansion of aluminium tube

Étude numérique du soudage par impulsion magnétique /

Numerical modeling and experimental analysis of deformation behaviors during electromagnetic flaring process of thin-walled copper tubes

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