Study On Magnetic Pulse Flanging Process Of AA6063 Aluminum Alloy Curved Plate And Inductor Failure

With the increasing demand of various industries and lightweight requirements,complex shape aluminum alloy plates are widely used in aerospace,vehicle and home appliance industries.In the traditional forming process,the low geometric accuracy caused by server spring-back and the poor surface quality resulting in the poor painting quality are two major problems faced by curved aluminum alloy plates.The electromagnetic forming(EMF)through non-contact Lorentz force to achieve workpiece forming at a high rate,not only the surface quality of workpiece can be improved,but also the material formability can be further improved.The inductor is the core component of EMF,and the repeated current loading on it will inevitably affect its durability,so it is necessary to study the failure of inductor to improve the service life of inductor.This paper takes AA6063 aluminum alloy curved plate as the research object,and studies the electromagnetic flanging process of curved plate and the failure of curved inductor.Firstly,according to the forming characteristics requirements of the curved plates,the corresponding die and coil were designed,and the initial profile of the workpiece was designed by using the geometric design method of unfold-bend.The electromagnetic flanging model of curved plate was established by LS-DYNA software,and the accuracy of the model was proofed by experimental method.By simulation method,the flanging behavior of curved plate was analyzed by means of electromagnetic force,impact process and strain state,and the non-uniform deformation behavior was obtained.Secondly,based on the numerical model,an improved initial profile method considering radial strain was proposed and the initial profile of the curved plate was improved.The numerical simulation results showed that the deviation between the flanging profile and the die profile was 0.229 mm,which significantly improved the flanging accuracy of the profile,and the feasibility of this method was verified by experiments.Finally,the magnetic pressure distribution of the curved sensor was discussed by means of experiment and simulation.The force of the curved sensor was also qualitatively analyzed.The location and failure mode of the sensor were obtained,and the results showed that the strength of packaging material determines the durability of the sensor.The temperature rise effect was analyzed based on solid heat transfer model.The results showed that the temperature rise effect was significant when the inductor performed continuous pulse discharge with a short discharge time interval.Based on the above analysis,a prediction model of temperature rise of curved sensor was established.The maximum number of continuous pulse discharge times allowed by the sensor at any time interval from 0 to 10 s can be obtained by using this model,and the accuracy of the model was verified by theoretical calculation.