Electromagnetic Metal Forming

Abstract

Some results of an experimental and theoretical investigation of the dynamic forming of thin-walled tubes and flat circular diaphragms by the electromagnetic metal forming process are given. The paper is divided into two parts. Part 1—The magnetic forming process is described and its use as a production technique is discussed. The process is a high strain-rate technique suitable for forming relatively light gauge material; the forces causing deformation result from the interaction of the current in specially constructed coils and the resulting eddy currents induced in the workpiece. The source of energy is a capacitor bank which can be discharged rapidly through the work-coil. The experiments described were performed using a specially constructed 16 kj discharge unit. The method of constructing work-coils and the failures experienced with these coils in service are described. Thin-walled copper and aluminium tubes were expanded by means of internal solenoidal work-coils of various lengths. The strain distribution and forming efficiency is presented, together with results showing the variation of process efficiency with changes in the primary circuit parameters. The strain distribution for a circular aluminium alloy diaphragm bulged by means of a flat spiral coil is given. Typical primary current waveforms are given and the changes in waveform and discharge current frequency due to different workpiece materials and changes in primary circuit parameters are indicated. Part 2—An attempt is made to determine theoretically the forces acting on one of the aluminium alloy tubes expanded and described in the work of Part 1. The currents in the work-coil and workpiece are calculated using the experimentally determined current waveform and the calculated value of workpiece inductance. A rudimentary method is developed for relating pressure on the workpiece to the primary and secondary currents and, using this, the radial motion of the tube is predicted. Although the analysis involves the use of a number of simplifications and approximations, the theoretical results obtained are of the same magnitude as would be expected by reference to other high-rate forming processes.