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I2FGEnergybasedHighVelocityForming

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ImpulseForming

EnergybasedHighVelocityForming

HighVelocity
Hydroforming

Electromagneticforming

EnergybasedHigh
VelocityForming

Definition

HighVelocityMechanical
Forming

Electromagneticforming(EMF)wasinventedbyHarveyandBrowerin1961[US2976907].Thistechnology
includesallproductionprocessesusingtheenergypulsedofmagneticfieldsinordertoapplyLorentzforces
andthusdeformaworkpiecemadeofanelectricallyhighlyconductivematerial.

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Processvariants
Dependingonthegeometryandthesetupthefollowingmajorprocessvariantscanbedistinguished.
Theseare
theelectromagneticcompressionoftubeswhicharepositionedinsideatypicallycylindricaltoolcoil,

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theelectromagneticexpansionoftubesinwhichatypicallycylindricaltoolcoilispositioned,

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theelectromagneticformingofflatsheetswithasuitable(oftenaspirallywound)flatcoil,and

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theelectromagneticformingofthreedimensionallypreformedsheetswithanaccordinglyshapedtoolcoil.

Moreexoticprocessvariantsare
electromagneticformingwithadischarged(andnotaninduced)currentintheworkpiece[Fur62]and
theelectromagneticformingwithattractiveforces,bywhichconvexformscanbeproducedinsuchpositions
whichcannotbereachedfromtheotherside[Pfe64,Fur62,Bir61].

Processprinciple
Theprincipleofelectromagneticformingisbasedonthemutualinductionconcept.Thetypicalsetupconsistsof
apulsedpowergenerator,
atoolcoilincludingafieldshaperifapplicable,and
theworkpiece.(Iftheelectricalconductivityoftheworkpieceisinsufficient,asocalleddrivercanbeused
toestablishtherequiredLorentzforces.)

Inordertostarttheprocess,thechargedcapacitorofthepulsedpowergeneratorisdischargedbyclosingof
thehighcurrentswitch.Consequently,adampedsinusoidalcurrentflowsthroughthetoolcoilinducinga
magneticfieldandasecondarycurrentintheworkpiece,whichisdirectedopposedtothecoilcurrent.Dueto
theskineffect,bothcurrentsareconcentratednearthesurfacesfacingeachother.Thesecondarycurrent
shieldsthemagneticfield,whichisconsequentlyconcentratedinthesmallgapbetweentoolcoilandworkpiece.
Accordingto[Kad59],theefficiencyofthisshieldingdependson
thefrequencyofthedischargingcurrent,
theworkpiecegeometry(radiusandwallthickness),
theelectricalconductivityofthematerial,and
thetime.

Theenergydensitystoredinthemagneticfieldiscorrelatedtoapressurep(z,t)actingorthogonaltothefield
andthecurrent,whichcanbecalculatedfromthemagneticfieldoutsidetheworkpieceHa(t,z),thepenetrated
magneticfieldHi(t,z),andthepermeability0as

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Fieldshapers
Inmanypracticalapplicationsthesetupforelectromagnetictubecompressionissupplementedbyasocalled
fieldshaperorfieldconcentrator,i.e.ausuallyaxissymmetricpartwithoneorseveralaxialslotsmadeofa
materialofhighelectricalconductivity,whichispositionedbetweentoolcoilandworkpiece.Inthesecases,the
coilcurrentinducesasecondarycurrentinthefieldshapersurface(skineffect),whichinturninducesacurrent
intheworkpiece.

Advantagesanddisadvantagesofafielfshaperapplication
Theapplicationofafieldshaperfeaturesseveraladvantagesase.g.
anincreasedprocessflexibilitybyadaptingoneandthesametoolcoiltoformingtasksandworkpiecesof
differentdiameters,lengthsandcrosssectiongeometries[Row67,Bau80]
areductionofthecoilload[Kim59,Lan93]andthus
anincreaseofthecoillifetime
thepossibilityforacombinedapplicationofdifferenttoolcoilsviaoneandthesamefieldshapere.g.inorder
tocompressaworkpiecedirectlyafteraninductiveheating[Hah04,Uhl03a,Uhl03b]

Themajordisadvantagesare
areducedprocessefficiency[Fur57,Bau80]
aninhomogeneouspressuredistributionalongthecircumference

Inprinciple,theuseofafieldshaperisnotlimitedtocompression[Neu88],buttheapplicationin
electromagneticexpansionorsheetmetalformingprocessesisrare.
backtotop

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2010InstituteofFormingTechnologyandLightweightConstruction
TechnischeUniversittDortmundBaroperStrae303D44227DortmundGermany
phone:+49(0)231/7552660fax:+49(0)231/7552489email:office@i2fg.org

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