Sheet metal electromagnetic forming using a flat spiral coil: Experiments, modeling, and validation

Abstract

Abstract In this paper, we present a novel study on electromagnetic forming (EMF) comprises experiments, modeling, and validation. Free bulging of aluminum sheet metals was performed in an instrumented SMU1500 EMF machine for a range of energies using a custom-made die tool. Special regard is given to the description of the materials and methods in the experimental phase and in the validation of the proposed model during the modeling stage. An enhanced model that couples electrical and magnetic phenomena is proposed, aiming to compute the electromagnetic forces (which are subsequently used) into a mechanical uncoupled simulation, to predict the sheet movement via a finite element method. The experimental results had a satisfactory agreement with the calculated and simulated predictions, establishing the significance of this analysis method. The experimental validation carried out highlights the importance of the prediction of discharge current, the magnetic field, and the influence of a coupled workpiece on the distribution of electromagnetic force (and subsequent deformed profile of the workpiece).