Effect of thickness and energy on electromagnetic compression of AA6061 tube

Abstract

Electromagnetic forming (EMF) has many applications in the automobile, structural, and other related areas due to its advantages such as reduced springback, wrinkling, and enhanced formability of deformed parts. Deformation of the workpiece depends on various process parameters such as applied energy level; system parameters such as inductance, capacitance, and resistance; and workpiece geometry such as thickness, and shape. These parameters control the current pulse, magnetic field, and Lorentz force. In the present study, effects of workpiece thickness, applied energy level, and process parameters on the deformation behavior of an AA6061 Al tube were studied. An attempt was also made to correlate discharge energy and process parameters with tube deformation. Finite-element (FE) analysis was performed to validate the experimental results. Various parameters such as the Lorentz force, magnetic field, and current density across the workpiece (tube), which cannot be measured experimentally, were numerically computed and correlated with the resulting nature of tube deformation. Aluminum alloy (AA) 6061 tubes with wall thicknesses of 1, 1.7, and 2.4 mm were deformed using a 4-turn bitter copper coil connected to a 40 kJ capacitor bank. In the present case, the intermediate wall thickness of the workpiece showed a higher efficiency for deformation. Moreover, reasonably good agreement was observed between the experimental and FE-simulated results.

This is a preview of subscription content, log in to check access.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

References

  1. 1.

    Yu HP, Li CF (2007) Effects of coil length on tube compression in electromagnetic forming. Trans Nonferr Met Soc China 17(6):1270–1275

    Article  Google Scholar 

  2. 2.

    Bartels G, Schätzing W, Scheibe HP, Leone M (2009) Comparison of two different simulation algorithms for the electromagnetic tube compression. Int J Mater Form 2(1):693

    Article  Google Scholar 

  3. 3.

    Shabanpour M, Arezoodar AF (2016) Multi-objective optimization of the depth of bead and tearing in electromagnetic tube compression forming. Int J Adv Manuf Technol 87(1–4):867–875

    Article  Google Scholar 

  4. 4.

    Haratmeh HE, Arezoodar AF, Farzin M (2017) Numerical and experimental investigation of inward tube electromagnetic forming. Int J Adv Manuf Technol 88(5–8):1175–1185

    Article  Google Scholar 

  5. 5.

    Savadkoohian H, Arezoodar AF, Arezoo B (2017) Analytical and experimental study of wrinkling in electromagnetic tube compression. Int J Adv Manuf Technol 93(1–4):901–914

    Article  Google Scholar 

  6. 6.

    Demir OK, Psyk V, Tekkaya AE (2010) Simulation of tube wrinkling in electromagnetic compression. Prod Eng Res Dev 4(4):421–426

    Article  Google Scholar 

  7. 7.

    Guo YB, Wen Q, Horstemeyer MF (2005) An internal state variable plasticity-based approach to determine dynamic loading history effects on the material property in manufacturing processes. Int J Mech Sci 47(9):1423–1441

    Article  Google Scholar 

  8. 8.

    Gharghabi P, Dordizadeh P, Niayesh K (2011) Impact of metal thickness and field shaper on the time-varying processes during impulse electromagnetic forming in tubular geometries. J Korean Phys Soc 59(61):3560–3566

    Article  Google Scholar 

  9. 9.

    Zhong L, Lu C, Shujie L, Mei W, Junping L (2015) Electromagnetic forming with solenoid coil. In: Seventh international conference on measuring technology and mechatronics automation, IEEE, 13–14 June 2015, Nanchang, China

  10. 10.

    Park H, Lee J, Kim SJ, Lee Y, Kim D (2016) Parametric study on numerical simulation of the electromagnetic forming of DP780 steel workpiece with aluminum driver sheet. J Phys Conf Ser 734(3):032085

    Article  Google Scholar 

  11. 11.

    Cui X, Mo J, Li J, Xiao X (2017) Tube bulging process using multidirectional magnetic pressure. Int J Adv Manuf Technol 90(5–8):2075–2082

    Article  Google Scholar 

  12. 12.

    Haiping YU, Chunfeng LI (2009) Effects of current frequency on electromagnetic tube compression. J Mater Proc Technol 209(2):1053–1059

    Article  Google Scholar 

  13. 13.

    Ahmed M, Panthi SK, Ramakrishnan N, Jha AK, Yegneswaran AH, Dasgupta R, Ahmed S (2011) Alternative flat coil design for electromagnetic forming using FEM. Trans Nonferr Met Soc China 21(3):618–625

    Article  Google Scholar 

  14. 14.

    Vivek A, Kim KH, Daehn GS (2011) Simulation and instrumentation of electromagnetic compression of steel tubes. J Mater Proc Technol 211(5):840–850

    Article  Google Scholar 

  15. 15.

    Shang J, Hatkevich S, Wilkerson L (2012) Comparison between experimental and numerical results of electromagnetic tube expansion. In: 12th international LS-DYNA users conference, 3–5 June 2012, Detroit, USA

  16. 16.

    Cao Q, Han X, Lai Z, Xiong Q, Zhang X, Chen Q, Xiao H, Li L (2015) Analysis and reduction of coil temperature rise in electromagnetic forming. J Mater Proc Technol 225:185–194

    Article  Google Scholar 

  17. 17.

    Rajak AK, Kore SD (2018) Numerical simulation and experimental study on electromagnetic crimping of the aluminium terminal to copper wire strands. Electr Power Syst Res 163:744–753

    Article  Google Scholar 

  18. 18.

    Li C, Zhao Z, Li J, Li Z (2005) The effect of tube length on magnetic pressure in tube electromagnetic bulging. J Mater Proc Technol 166(3):381–386

    Article  Google Scholar 

  19. 19.

    Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures, and pressures. Eng Fract Mech 21(1):31–48

    Article  Google Scholar 

  20. 20.

    Psyk V, Risch D, Kinsey BL, Tekkaya AE, Kleiner M (2011) Electromagnetic forming—a review. J Mater Proc Technol 211(5):787–829

    Article  Google Scholar 

  21. 21.

    Doley JK, Kore SD (2016) A study on friction stir welding of dissimilar thin sheets of aluminum alloys AA5052–AA6061. J Manuf Sci Eng 138(11):114502

    Article  Google Scholar 

  22. 22.

    Zhang X, Zhang M, Sun L, Li C (2018) Numerical simulation and experimental investigations on TA1 titanium alloy rivet in electromagnetic riveting. Arch Civ Mech Eng 18(3):887–901

    Article  Google Scholar 

  23. 23.

    Wang Z, Chen C, Liu C, Gao T (2019) Research on electromagnetic tube compression of small diameter aluminum alloy tube and efficiency of field shaper. J Braz Soc Mech Sci Eng 41(4):177

    Article  Google Scholar 

Download references

Acknowledgements

The authors thank the Director, CSIR-AMPRI, Bhopal; Mr. Rakesh Kaul, Head, LMPD, RRCAT, Indore; and Dr. P. Ganesh, Scientific officer (G), RRCAT, Indore for providing facilities for carrying out the study.

Author information

Affiliations

Authors

Corresponding author

Correspondence to Amitabh Shrivastava.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Technical Editor: Adriano Fagali de Souza.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Shrivastava, A., Telang, A., Jha, A.K. et al. Effect of thickness and energy on electromagnetic compression of AA6061 tube. J Braz. Soc. Mech. Sci. Eng. 42, 372 (2020). https://doi.org/10.1007/s40430-020-02456-6

Download citation

Keywords

  • Electromagnetic forming
  • High-velocity forming
  • FE simulation
  • Aluminum alloy 6061