Title: Investigation of the Effects of the Coil Design on Electro- Magnetic Forming of a Thin-Walled Aluminum Tubular Material
Abstract: In this study, a thin-walled aluminum tube was expanded using the electro-magnetic forming (EMF) process. Two different designs of coil were developed by using the EMF simulation. A commercial FEM code, LS-DYNA, was used to simulate the process with different coil designs. In this study, different coil designs were studied to expand a thin-walled aluminum tubes using EMF. The initial thickness of aluminum tube was 0.254 mm (0.01 in.) and the material of tube was Aluminum 3000 (Al-3000). This aluminum material is known to be difficult for expanding larger than 9% expansion ratio at a given thickness. To evaluate the performance of coil to expand tube without failures, two different coils were designed and manufactured to have two different gaps between the coil and the workpiece. Preliminary FEM simulations were conducted to determine the baseline design of coil and after preliminary EMF tests, the coil design was changed. Tubular samples were tested with two different coils and two different die sets (e.g., 10 and 12% expansion ratios). The EMF process was numerically modeled by using a commercial FEM code, LS-DYNA. A newly developed “electro-magnetism module” was used for process simulations and the simulation results were compared with experiments.
Publication Year: 2012
Publication Date: 2012-01-01
Language: en
Type: article
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