Pulsed electromagnetic attraction of sheet metals – Fundamentals and perspective applications

The paper is dedicated to the study of pulsed electromagnetic attraction processes which can deform ferromagnetic sheet metal materials such as low carbon steels using low frequency discharges. The analytical model based upon the solution of Maxwell equations explains that magnetic forces are prevailing over the Lorentz forces for low frequency discharges. For electromagnetic forming (EMF) processes employing ferromagnetic sheet metal blanks of low electrical conductivity with relatively slow electric discharges, the magnetic forces should be taken into account in order to achieve a correct representation of electromagnetic forces applied to the blank. An engineering estimate on the size of magneto-static forces and Lorentz-forces is the outcome of the analytical work. In addition to analytical work and validation of the proposed engineering estimate of attracting forces, a single turn coil is introduced which is more robust than previous designs with multiple frequencies and interrupted discharges. The simplified setup only requires a rather slow single frequency low voltage electric discharge which allows for using cheaper and longer life capacitors, substantially reduces the safety implications and also extends the life of the coil insulation.