Abstract

Electromagnetic crimping is a solid state, high-speed, and high strain-rate joining process. Finite element analysis, as well as experimental study, was carried out on three types of field shapers, namely, tapered, taper-stepped, and stepped. In all three field shapers, the effective length, outer diameter, inner diameter, total length, and materials properties were constant. These field shapers were kept inside the same multi-turn solenoid coil for all the experiments. It was found that the taper-stepped field shaper results better regarding impact velocity, Lorentz force, temperature generation, less heating, and uniformity in crimping among the three types of field shapers.

Issue Section:
Technical Brief
Keywords:
electromagnetic crimping, temperature distribution, types of field shaper, finite element method, modeling and simulation, crimping and joining
Topics:
Copper, Current density, Finite element analysis, Joining, Magnetic fields, Materials properties, Modeling, Rods, Simulation, Temperature, Solenoids, Finite element methods, Machinery, Aluminum, Heating, Temperature distribution, Temperature measurement

References

1.
Demchenko
,
V. F.
,
Ryabchenco
,
V. R.
,
Bocharnikov
,
I. V.
, and
Zvoliskil
,
I. V.
,
1992
, “
Calculating the Collision Speed of Al Shells in Magnetic Pulse Welding
,”
Paton Weld. J.
,
4
(
6
), pp.
23
–
25
.
2.
Song
,
F. M.
,
Zhang
,
X.
,
Wang
,
Z. R.
, and
Yu
,
L. Z.
,
2004
, “
A Study of Tube Electromagnetic Forming
,”
J. Mater. Process. Technol.
,
151
(
1–3
), pp.
372
–
375
. 10.1016/j.jmatprotec.2004.04.089
Google Scholar
Crossref
Search ADS
 
3.
Kapil
,
A.
, and
Sharma
,
A.
,
2015
, “
Magnetic Pulse Welding: An Efficient and Environmentally Friendly Multi-Material Joining Technique
,”
J. Cleaner Prod.
,
100
(
Aug.
), pp.
35
–
58
. 10.1016/j.jclepro.2015.03.042
Google Scholar
Crossref
Search ADS
 
4.
Haiping
,
Y.
,
Chunfeng
,
L.
, and
Jianghua
,
D.
,
2009
, “
Sequential Coupling Simulation for Electromagnetic–Mechanical Tube Compression by Finite Element Analysis
,”
J. Mater. Process. Technol.
,
209
(
2
), pp.
707
–
713
. 10.1016/j.jmatprotec.2008.02.061
Google Scholar
Crossref
Search ADS
 
5.
Yu
,
H.
,
Li
,
C.
,
Zhao
,
Z.
, and
Li
,
Z.
,
2005
, “
Effect of Field Shaper on Magnetic Pressure in Electromagnetic Forming
,”
J. Mater. Process. Technol.
,
168
(
2
), pp.
245
–
249
. 10.1016/j.jmatprotec.2005.01.001
Google Scholar
Crossref
Search ADS
 
6.
Fan
,
Z.
,
Yu
,
H.
, and
Li
,
C.
,
2015
, “
Plastic Deformation Behavior of Bi-Metal Tubes During Magnetic Pulse Cladding: FE Analysis and Experiments
,”
J. Mater. Process. Technol.
,
229
(
Mar.
), pp.
230
–
243
. 10.1016/j.jmatprotec.2015.09.021
7.
Suzuki
,
H.
,
Murata
,
M.
, and
Negishi
,
H.
,
1987
, “
The Effect of a Field Shaper in Electromagnetic Tube Bulging
,”
J. Mech. Work. Technol.
,
15
(
2
), pp.
229
–
240
. 10.1016/0378-3804(87)90036-2
Google Scholar
Crossref
Search ADS
 
8.
Chaharmiri
,
R.
, and
Arezoodar
,
A. F.
,
2017
, “
The Effect of Stepped Field Shaper on Magnetic Pressure and Radial Displacement in Electromagnetic Inside Bead Forming: Experimental and Simulation Analyses Using Maxwell and Abaqus Software
,”
ASME J. Manuf. Sci. Eng.
,
139
(
6
), p.
061003
. 10.1115/1.4035219
Google Scholar
Crossref
Search ADS
 
9.
Li
,
S.
,
Cui
,
X.
, and
Li
,
G.
,
2017
, “
Multi-Physics Analysis of Electromagnetic Forming Process Using an Edge-Based Smoothed Finite Element Method
,”
Int. J. Mech. Sci.
,
134
(
Dec.
), pp.
244
–
252
. 10.1016/j.ijmecsci.2017.10.018
Google Scholar
Crossref
Search ADS
 
10.
Li
,
S.
,
Cui
,
X.
,
Feng
,
H.
, and
Wang
,
G.
,
2017
, “
An Electromagnetic Forming Analysis Modelling Using Nodal Integration Axisymmetric Thin Shell
,”
J. Mater. Process. Technol.
,
244
(
June
), pp.
62
–
72
. 10.1016/j.jmatprotec.2017.01.028
Google Scholar
Crossref
Search ADS
 
11.
Feng
,
H.
,
Cui
,
X. Y.
, and
Li
,
G. Y.
,
2017
, “
Coupled-Field Simulation of Electromagnetic Tube Forming Process Using a Stable Nodal Integration Method
,”
Int. J. Mech. Sci.
,
128–129
(
Aug.
), pp.
332
–
344
. 10.1016/j.ijmecsci.2017.05.003
Google Scholar
Crossref
Search ADS
 
12.
Lee
,
T.
,
Zhang
,
S.
,
Vivek
,
A.
,
Kinsey
,
B.
, and
Daehn
,
G.
,
2018
, “
Flyer Thickness Effect in the Impact Welding of Aluminum to Steel
,”
ASME J. Manuf. Sci. Eng.
,
140
(
12
), p.
121002
. 10.1115/1.4041247
Google Scholar
Crossref
Search ADS
 
13.
Cui
,
X.
,
Li
,
S.
,
Feng
,
H.
, and
Li
,
G.
,
2017
, “
A Triangular Prism Solid and Shell Interactive Mapping Element for Electromagnetic Sheet Metal Forming Process
,”
J. Comput. Phys.
,
336
(
May
), pp.
192
–
211
. 10.1016/j.jcp.2017.02.014
Google Scholar
Crossref
Search ADS
 
14.
Meyers
,
M. A.
,
2004
,
Dynamic Behavior of Materials
,
John Wiley & Sons, Inc.
,
New York
.
15.
Eide
,
H. O. S.
, and
Melby
,
E. A.
,
2013
, “
Blast Loaded Aluminium Plates Experiments and Numerical Simulations
,” Master’s thesis,
Norwegian University of Science and Technology
, pp.
1
–
139
.
16.
Maria
,
C.
,
2009
,
Technology of EHIS (Stamping) Applied to Production of Automotive Parts
.
Saint-Petersburg State Polytechnical University, Department of Applied Mathematics
. http://wwwmayr.in.tum.de/konferenzen/Jass09/courses/3/Churilova_paper.pdf
17.
Schwer
,
L. E.
 and
Windsor
,
C. A.
,
2009
, “
Aluminium Plate Perforation: A Comparative Case Study Using Lagrange With Erosion, Multi-Material ALE, and Smooth Particle Hydrodynamics
,”
7th European LS-DYNA Conference
,
Stuttgart, Germany
,
June
, vol.
10
.
Copyright © 2019 by ASME
You do not currently have access to this content.