Research Of Electromagnetic Hemming Of Aluminum Alloy

With the daily huge increasing demand of autos,to reduce the consumption of energy and emissions of vehicle exhaust need to be fixed currently.Lightweight of automobile could reduce the consumption of energy and now the main used materials in China for lightweight is magnesium alloy,aluminum alloy and composite material.Edging and shaping is the most important technique in automobile panel stamping process,and its results directly affect the outer panels’quality.Using aluminum alloy for outer panels could realize the lightweight of automobile.However,the aluminum alloy has low elongation and formability,also its stiffness is low,which leads the forming workpiece has high recovery.Thus,new processing method need to be used since the general forming method cannot meet the requirements of practical production.Electromagnetic forming edging process,is a new technique to use electromagnetic forming in edging and shaping.Electromagnetic forming is a kind of high energy rate forming,and according to its charge and discharge to capacitive equipments in split second,the changing magnetic field is produced around coils,and eddy current is inducted and produced in the changed magnetic field,and then workpiece is formed.This article researches the relationship between edge forming angle and voltage,the relationship between edge forming angle and board package edge height,and the relationship between edge forming angle and location height of board relative bottom coil according to three electromagnetic forming edging tests.When the board package edge height and location height of board relative bottom coil are fixed,the edge forming angle is proportional to voltage within certain limits.When the voltage and location height of board relative bottom coil are fixed,the forming is obvious if the ratio of board package edge height and coil height is between 69%～89%.When the voltage and board package edge height are fixed,the forming is obvious if height of board relative bottom coil is between 7mm～13m.This article used finite element modeling methods to analyze the tests results.Since the electromagnetic forming design has many physical fields,the theoretical analysis is much more complicated and the finite element modeling methods are used for model analysis.This article has combined the tests and modeling,to prove the accuracy of experimental result,and realized the finite element simulated analysis of parameterized and intelligent electromagnetic edging according to design and development of finite element secondary development software of electromagnetic edging.