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176:(pink). The current flowing the workpiece produces a corresponding opposite magnetic field which rapidly repels the workpiece from the forming coil, reshaping the workpiece — in this case, compressing the diameter of the cylindrical tube. The reciprocal forces acting against the forming coil are resisted by the '
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A special coil is placed near the metallic workpiece, replacing the pusher in traditional forming. When the system releases its intense magnetic pulse, the coil generates a magnetic field which in turn accelerates the workpiece to hyper speed and onto the die. The magnetic pulse and the extreme
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that induce a current in the workpiece and a corresponding repulsive magnetic field, rapidly repelling portions of the workpiece. The workpiece can be reshaped without any contact from a tool, although in some instances the piece may be pressed against a die or former. The technique is sometimes
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Mechanical contact with the workpiece is not required; this avoids surface contamination and tooling marks. As a result, a surface finish can be applied to the workpiece before forming.
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A pinched aluminium can, produced from a pulsed magnetic field created by rapidly discharging 2 kilojoules from a high-voltage capacitor bank into a 3-turn coil of heavy gauge wire.
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The forming process is most often used to shrink or expand cylindrical tubing, but it can also form sheet metal by repelling the work piece onto a shaped
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deformation speed transforms the metal into a visco-plastic state – increasing formability without affecting the native strength of the material. See the
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Forming can be combined with joining and assembling with dissimilar components including glass, plastic, composites and other metals.
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of the metal work piece, causing permanent deformation. The metal forming process occurs extremely quickly (typically tens of
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Electromagnetic forming has a number of advantages and disadvantages compared to conventional mechanical forming techniques.
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and deceleration, mass of the work piece plays a critical role during the forming process. The process works best with good
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In practice the metal workpiece to be fabricated is placed in proximity to a heavily constructed coil of wire (called the
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243:. High-quality joints can be formed, either by electromagnetic pulse crimping with a mechanical interlock or by
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172:(orange) producing a rapidly changing magnetic field which induces a current to flow in the metallic
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Non-conductive materials cannot be formed directly, but can be formed using a conductive drive plate
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188:). A huge pulse of current is forced through the work coil by rapidly discharging a high-voltage
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149:. The induced current creates a corresponding magnetic field around the conductor (see
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The references used may be made clearer with a different or consistent style of
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The high voltages and currents involved require careful safety considerations
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356:"Electromagnetic Hemming Machine And Method For Joining Sheet Metal Layers"
223:) and, because of the large forces, portions of the workpiece undergo high
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with a true metallurgical weld. Since the forming operation involves high
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An
English translation of the Russian book by Belyy, Fertik, and Khimenko
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327:"Materials and Manufacturing: Electromagnetic Forming of Aluminum Sheet"
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The high work coil current (typically tens or hundreds of thousands of
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Department of
Materials Science and Engineering, Ohio State University
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Improved formability (the amount of stretch available without tearing)
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Abdelhafeez, Ali M.; Nemat-Alla, M.M.; El-Sebaie, M.G. (2013-03-05).
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Lubricants are reduced or are unnecessary, so forming can be used in
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450:"Industrial Application of the Electromagnetic Pulse Technology"
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Single-sided dies are sufficient, which can reduce tooling costs
215:) creates ultra strong magnetic forces that easily overcome the
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International
Journal of Applied Electromagnetics and Mechanics
869:"FEA of electromagnetic forming using a new coupling algorithm"
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425:"FEA of electromagnetic forming using a new coupling algorithm"
259:, but it can be adapted to work with poorer conductors such as
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When the switch is closed, electrical energy stored in the
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process for electrically conductive metals, most commonly
379:"Resources on Electromagnetic and High Velocity Forming"
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A rapidly changing magnetic field induces a circulating
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Ali M. Abdelhafeez, M.M. Nemat-Alla and M.G. El-Sebaie
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710:
609:
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479:"Electromagnetic Forming of Cylindrical Components"
204:. This creates a rapidly oscillating, ultra strong
105:. The workpiece is reshaped by high-intensity
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227:reaching velocities of up to 300 m/s.
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62:Learn how and when to remove this message
402:"Electromagnetic Metal Forming Handbook"
73:
859:
334:Pacific Northwest National Laboratory
7:
281:Wrinkling can be greatly suppressed
132:magnetic pulse forming illustration
93:) is a type of high-velocity, cold
267:Comparison with mechanical forming
14:
308:The principle disadvantages are;
287:Close tolerances are possible as
168:(left) is discharged through the
119:electromagnetic pulse technology
20:
360:US Patent and Trademark Office
1:
291:can be significantly reduced.
245:electromagnetic pulse welding
274:Some of the advantages are;
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904:Electromagnetic radiation
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147:electromagnetic induction
632:Electrohydraulic forming
637:Electromagnetic forming
83:Electromagnetic forming
622:Casting (metalworking)
208:around the work coil.
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178:supportive coil casing
151:Pinch (plasma physics)
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843:Tools and terminology
253:electrical conductors
206:electromagnetic field
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134:for a visualization.
115:high-velocity forming
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672:Progressive stamping
748:Finishing processes
885:10.3233/JAE-131653
255:such as copper or
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711:Joining processes
642:Explosive forming
610:Forming processes
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52:November 2019
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29:This article
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914:Pulsed power
876:
872:
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702:Tube bending
657:Hydroforming
636:
532:Metalworking
491:. Retrieved
487:the original
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468:. Retrieved
461:the original
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432:. Retrieved
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414:. Retrieved
410:the original
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391:. Retrieved
387:the original
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368:. Retrieved
364:the original
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345:. Retrieved
338:the original
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307:
273:
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249:acceleration
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231:Applications
225:acceleration
221:microseconds
210:
185:
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177:
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170:forming coil
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136:
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91:magneforming
90:
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58:
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813:Fabrication
761:Galvanizing
601:Sheet metal
591:Fabrication
575:fabrication
125:Explanation
898:Categories
833:Metallurgy
776:Patination
596:Piece work
493:2006-06-06
470:2010-08-01
434:2013-01-15
416:2006-08-06
393:2006-04-06
370:2005-09-02
347:2006-06-09
320:References
301:conditions
299:clean-room
289:springback
239:at a high
155:Lenz's Law
87:EM forming
44:footnoting
828:Machining
823:Jewellery
791:Polishing
756:Anodizing
733:Soldering
647:Extrusion
198:spark gap
190:capacitor
186:work coil
174:workpiece
143:conductor
103:aluminium
838:Smithing
728:Riveting
723:Crimping
692:Spinning
677:Punching
662:Stamping
257:aluminum
241:velocity
194:ignitron
180:(green).
145:through
40:citation
848:Welding
818:Forming
808:Casting
786:Plating
781:Peening
738:Welding
718:Brazing
697:Swaging
687:Sinking
682:Rolling
652:Forging
627:Drawing
617:Coining
584:General
571:Forming
213:amperes
113:called
95:forming
202:switch
107:pulsed
99:copper
464:(PDF)
453:(PDF)
341:(PDF)
330:(PDF)
261:steel
200:as a
196:or a
101:and
42:and
881:doi
237:die
117:or
89:or
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