Sequential coupling of electromagnetic–structural simulation for compression welding of tubular jobs

Abstract

This work adopts a simplified analytical approach to design an axi-symmetric bitter circular coil and presents a sequential-coupled simulation of electromagnetic welding for tubular jobs using finite element analysis. A three-dimensional axi-symmetric transient electromagnetic model is proposed to predict the developed magnetic field and pressure, which is sequentially coupled to the mechanical model to obtain the deformations occurring on the mating members. Results in the form of changes in impact velocity, shear stress, and effective plastic strain induced on the outer wall of the flyer tube with varying process parameters, via input voltage and initial angle of taper of inner solid plug during welding simulation are graphically shown. Based on the results of the coupled finite element simulation, a weldability window for effective welding of tubular jobs is proposed.

Numerical and experimental study of electromagnetic induction heating process for bolted flange joints

“…During EMIH process, the conduction current density plays a decisive role in controlling the temperature distribution and final heating time. 20 A larger input current density will shorten the heating time but increase the maximum thermal stress at the same time. If the current density can be adjusted, we may find a moderate balance between efficiency and safety.…”

“…Therefore, finite element method (FEM)-based numerical simulation has become a popular mean used by many researchers to analyze the induction heating process in industrial applications, including metal forming, 6–13 melting 14 and molding, 15 crystal growing, 16 wafer packaging, 17,18 and welding process. 19,20 Cho 6 established a cost-effective coupled electromagnetic-thermal model to numerically analyze the solutions of both stationary and moving workpiece under low frequency induction heating system, which could predict more precise results of temperature distribution in the variable magnetic field than the previous model. Otio 7 mainly focused on the electrical parameter optimization by searching optimal frequency to obtain the maximum deformation of workpiece in the electromagnetic forming (EMF) process.…”

“…Khan et al. 19,20 conducted a three-dimensional (3-D) numerical simulation to evaluate magnetic pressure distribution in the target area, trying to make the best use of the input energy in EMW process with the optimal coils, field shapers and workpiece location and consequently proposing a weldability window for effective tubular welding.…”

Current frequency effect on electromagnetic tube expansion

“…The numerical investigation is performed by various software using loosely coupled and sequentially coupled techniques. 3–5 The advantage of the sequential approach is that the effect of WP deformation on electromagnetic force distribution is considered and hence it has better accuracy over a loosely coupled approach. 4,6 Electrical and mechanical parameters involved in the EMF process decide the resultant forming of WP.…”