Research On The Forming Mechanism And The Process Parameters Of Electromagnetic Tube Compression

The electromagnetic tube compression is a high-speed electromagnetic pulse forming process,is used when the metal tube is connected with metal or non-metal tube and rod,and can replace the conventional forming method.The forming electromagnetic force is used to cause the tube deformation by the field shaper and coil,and the parameter variation of the field shaper and the working coil has a direct influence on the electromagnetic force efficiency and the tooling stability,the efficiency of electromagnetic tube compression and the electromagnetic force will be influenced by the difference in the metal material property and the geometric parameter of the tube.In order to study the mechanism of electromagnetic tube compression and the influence of various process parameters on the electromagnetic force and forming efficiency based on the field shaper and coil.In this paper,the various process parameters will be studied by theoretical analysis,numerical simulation and experimental research.In the research,the field shaper is regarded as a special type of single-turn conventional coil by the theoretical analysis.The value and the distribution of electromagnetic force are mainly related to the current and the length of the field shaper working area,and the material conductivity,magnetic permeability,length and outer radius of the tube,the gap of tube and field shaper.Through numerical simulation software analysis,it is reasonable to determine that the working coil turns are 6 turns,the angle of inner slope of the field shaper is 40°,and the gap width of field shaper is 1mm.Based on the optimized parameters of the field shaper and coil,the 3003 aluminum alloy tube and the 6063 aluminum alloy tube with different tube lengths are studied separately by combining numerical simulation and experiment.The electromagnetic reduction efficiency,the diameter reduction ratio,and the uniformity of diameter reduction of 3003 aluminum tube are obviously better than 6063 aluminum tube under the same conditions.The peak of the discharge current is only related to the material of the tube and has nothing to do with the length of the tube.The value and distribution of the electromagnetic force of the two kinds of aluminum tubes are inversely proportional to the tube length.The longer the tube length,the smaller the axial length of the reduced diameter region.The uniformity of diameter reduction has no obvious relationship with tube length,and it is related to the material properties of tube,the uniformity of magnetic field force distribution and discharge conditions.The electromagnetic force uneven distribution along the aluminum tube and the material properties of tube are the main reasons for the unevenness of diameter reduction,and the accuracy of the numerical simulation is verified.