Study On Aluminum Tube And Sheet Bulging Of Electromagnetic Forming Processing

Electromagnetic forming is a kind of high-velocity forming technology based on the repulsive forces generated by opposite magnetic fields in adjacent conductors, which can significantly increase materials' forming limit. Coils are usually fixed in one position in traditional electromagnetic forming, and there is a limitation of strength of the working tool and the capacity of the capacitor bank, which makes it difficult to manufacture large parts.Suitable 2D FE models are designed to predict the forming process with a moving coil. In comparison with experimental values, simulation method can obtain accurate results. Then, effect factors named overlapping ration of adjacent discharge positions, discharge voltage, forming sequence and die dimension on tube homogeneous deformation is discussed. The result demonstrates that it is feasible to produce long-straight wall tubes using a small coil by electromagnetic incremental tube bulging. Furthermore, it provide a 45#Fe-mold outside the Aluminum tube to bulge more uniform.One disadvantage of the electromagnetic forming process is poor efficiency. This is because just a small part of energy is used for plastic deformation. In order to improve energy efficiency, this study analyzed the effect of different die dimensions and coil structures, through the comparison for profile, plastic deformation and energy efficiency after electromagnetic forming of aluminium alloy sheet. The validation of the simulation model is proved according to experiment value. When the die radius is approximately to the sum of coil radius and corner radius, the maximum values of plastic deformation energy and energy efficiency are obtained, respectively.