Designing of a Field Shaper for Electromagnetic Crimping of Multi-Tube-Tube and Multi-Tube-Rod in Single Discharge Energy

Abstract

Abstract This paper designed a unique field shaper, which can crimp multiple end tubes in single discharge energy. This design will surely provide an advantage of crimping different diameter tube-tube-tube and tube-tube-rod in single discharge energy. The design of the field shaper not only shows the feasibility of the multi-tube-tube and multi-tube-rod crimping for different electrical and fluid transfer applications but also explores the idea that multi-joining is also possible if carried out at the correct machine and tool parameters. The feasibility of the new process was proven by doing numerical analysis using the electromagnetic (EM) module of the ls-dyna software. Discussions on variables like current density, magnetic field, effective stress, impact velocity, and slit change are carried out. The work was validated using the tube deformation, the cross-sectional analysis of the crimped samples, and the impact velocity of the flyer tube that was measured using the PDV system. Post-processing of the samples was also carried out like a pull-out test, which justifies the numerical data interpreted. Some new important observation of the pressure waves generated during the process is discussed. Those intense pressure waves still exist after the peak current value is achieved during the current first cycle. As predicted, it may also be one of the reasons affecting the lifecycle of the field shaper. The design of the field shaper will provide a unique method for carrying out the multiple samples crimping in the single discharge energy and enhancing the production rate.