Finite Element Analysis of Electromagnetic Forming Process and Optimization of Process Parameters Using RSM

Abstract

Aluminium can benefit from the high-speed forming technique known as electromagnetic forming (EMF). EMF is increasingly used in automotive applications as a result of this capability. This technology depends on Lorentz force (Magnetic force) in the practical forming application which relies on different process parameters like forming a coil. A finite element model for the EMF process is built and studied in this work using the finite element analysis software ANSYS 2022 R1. The affecting process parameters are investigated using the Design of Experiments (DOE) approach. Response Surface Methodology (RSM) of the DOE approach is used by taking process parameters such as coil size, gap, and current density into account. The number of experiments is reduced by using Central Composite Design (CCD), an RSM model. To determine the optimal level of parameters, a magnetic force optimization study is carried out. The parameters of the EMF process (e.g., magnetic force) are investigated through a developed 2D finite element model and validated with available literature.