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.

References

1.
Kamal
,
M.
, and
Daehn
,
G. S.
,
2007
, “
A Uniform Pressure Electromagnetic Actuator for Forming Flat Sheets
,”
ASME. J. Manuf. Sci. Eng.
,
129
(
2
), pp.
369
379
.
2.
Kinsey
,
B.
,
Nassiri
,
A.
, and
Nassiri
,
A.
,
2017
, “
Analytical Model and Experimental Investigation of Electromagnetic Tube Compression With Axi-Symmetric Coil and Field Shaper
,”
CIRP Ann.
,
66
(
1
), pp.
273
276
.
3.
Saadouki
,
B.
,
Sapanathan
,
T.
,
Pelca
,
P. H.
,
Elghorba
,
M.
, and
Rachik
,
M.
,
2018
, “
Fatigue Damage in Fieldshaper Used During Electromagnetic Forming and Welding Process at High Frequency Impulse Current
,”
Int. J. Fatigue
,
109
, pp.
93
102
.
4.
Zelin
,
W. U.
,
Cao
,
Q.
,
Fu
,
J.
,
Li
,
Z.
,
Wan
,
Y.
,
Chen
,
Q.
,
Li
,
L.
, and
Han
,
X.
,
2020
, “
An Inner Field Uniform Pressure Actuator With High Performance and Its Application to Titanium Bipolar Plate Forming
,”
Int. J. Mach. Tools Manuf.
,
115
, pp.
103
121
.
5.
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
.
6.
Qui
,
L.
,
Wang
,
C.
,
Ahmed A
,
S.
,
Wang
,
B.
,
Zhang
,
W.
,
Weikang
,
G. E.
,
Chang
,
L.
, and
Yuwai
,
F.
,
2020
, “
Numerical Analysis of Tube Expansion by Electromagnetic Forming Using Magnetic Field Shaper
,”
IEEE Access
,
8
(
1
), pp.
196253
196263
.
7.
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
.
8.
Chaharmiri
,
R.
, and
Arezoodar
,
A. F.
,
2017
, “
The Effect of Various Stepped Field Shaper on Magnetic Pressure and Radial Displacement in Electromagnetic Inside Bead Forming: Experimental and Simulation Analysis Using Maxwell and Abaqus Software
,”
ASME, J. Manuf. Sci. Eng.
,
139
(
1
), p.
061003
.
9.
Li
,
F.
,
Jiang
,
J.
,
Cheng
,
H.
,
Xu
,
J.
,
Ge
,
X.
,
Li
,
H.
,
Zhao
,
J.
, and
Ran
,
Y.
,
2021
, “
Optimisation of the Field Shaper Parameters in Electromagnetic Pulse Crimping of Cable
,”
Int. J. Precis. Eng. Manuf.
,
22
(
10
), pp.
1693
1706
.
10.
Shen
,
T.
,
Li
,
C.
,
Zhou
,
Y.
,
Wu
,
H.
,
Wang
,
X.
, and
Xu
,
Q.
,
2022
, “
The Effect of Assembly of Coil and Field Shaper on Electromagnetic Pulse Crimping
,”
Energy Rep.
,
8
(
Suppl. 1
), pp.
1243
1248
.
11.
Kumar
,
D.
,
Kore
,
S. D.
, and
Nandy
,
A.
,
April 2021
, “
Finite Element Modeling of Electromagnetic Crimping of Cu-SS Tube-to-Tube Joint Along With Simulation of Destructive Testing for Strength Prediction of the Joint.
,”
ASME. J. Manuf. Sci. Eng.
,
143
(
4
), p.
041004
.
12.
Cai
,
G. X.
, and
Yuan F
,
G.
,
1998
, “
Stresses Around the Crack Tip Due to Electric Current and Self Induced Magnetic Field
,”
Adv. Eng. Softw.
,
29
(
3–6
), pp.
297
306
.
13.
Cai
,
G. X.
, and
Yuan F
,
G.
,
1999
, “
Electric Current Induced Stresses at the Crack Tip in Conductors
,”
Int. J. Fract.
,
96
(
3
), pp.
279
301
.
14.
Liu
,
T. J. C.
,
2008
, “
Thermo Electro Structural Coupled Analyses of Crack Arrest by Joule Heating
,”
Theor. Appl. Fract. Mech.
,
49
(
2
), pp.
171
184
.
15.
Satapathy
,
S.
,
Stefani
,
F.
, and
Saenz
,
A.
,
2004
, “
Crack Tip Behaviour Under Pulsed Electromagnetic Loading
,”
Proceedings of International 12th Symposium on Electromagnetic Launch Technology
,
IEEE
, pp.
106
-
110
.
16.
Basaran
,
C.
,
Lin
,
M.
, and
Ye
,
H.
,
2003
, “
A Thermodynamic Model for Electrical Current Induced Damage
,”
Int. J. Solids Struc.
,
40
(
26
), pp.
7315
7327
.
17.
Lin
,
H. Q.
,
Zhao
,
Y. G.
,
Gao
,
Z. M.
, and
Han
,
L. G.
,
2008
, “
Effect of Pulse Current Simulation on the Thermal Fatigue Crack Propagation of CHWD Steel
,”
Mater. Sci. Eng. A
,
478
(
1–2
), pp.
93
100
.
18.
Chu
,
Y.-Y.
, and
Lee
,
R.
,
2013
, “
Effect of Field Shaper Geometry on the Lorentz Force for Electromagnetic Sheet Impact Forming Process
,”
Proc. Inst. Mech. Eng. B
,
227
(
2
), pp.
324
332
.
19.
Psyk
,
V.
,
Risch
,
D.
,
Kinsey
,
B. L.
,
Tekkaya
,
A. E.
, and
Kleiner
,
M.
,
2011
, “
Electromagnetic Forming—A Review
,”
J. Mater. Process. Technol.
,
211
(
5
), pp.
787
829
.
20.
Wedding
,
C.
,
Hahn
,
M.
,
Daehn
,
G. S.
, and
Takkaya
,
A. E.
,
2014
, “
Uniform Pressure Electromagnetic Actuator, An Innovative Tool for Magnetic Pulse Welding
,”
Procedia CIRP
,
18
(
1
), pp.
156
161
.
21.
Vivek
,
A.
,
Kim
,
K. H.
, and
Daehn
,
G. S.
,
2011
, “
Simulation and Instrumentation of Electromagnetic Compression of Steel Tubes
,”
J. Mater. Process. Technol.
,
211
(
5
), pp.
840
850
.
22.
Shieh
,
J.
,
Huber
,
J. E.
, and
Fleck
,
N. A.
,
2006
, “
Fatigue Crack Growth in Ferroelectrics Under Electrical Loading
,”
J. Eur. German Soc.
,
26
(
1–2
), pp.
95
109
.
23.
Eplattenier
,
P. L.
,
Cook
,
G.
,
Ashcraft
,
C.
,
Burger
,
M.
,
Imbert
,
J.
, and
Worswick
,
M.
,
2009
, “
Introduction of an Electromagnetism Module in Ls-Dyna for Couple Mechanical-Thermal-Electromagnetic Simulations
,”
Steel Res. Int.
,
5
, pp.
80
85
.
24.
Sohail
,
A.
,
Syed
,
H. I. J.
,
Mushtaq
,
K.
,
Muhammas
,
F.
,
Aamir
,
M.
, and
Liaqat
,
A.
,
2018
, “
Numerical and Experimental Investigation of Johnson Cook Material Models for Aluminium Ai 6061T6 Alloy Using Orthogonal Machining Approach
,”
Adv. Mech. Engg.
,
10
(
9
), pp.
1
14
.
You do not currently have access to this content.