Investigation of large sheet deformation process in electromagnetic incremental forming

• Two die structures were designed to study the sheet forming process with coil discharge at different positions.
• It is difficult to control the forming accuracy with free die no matter what value of the coil rotation angle is.
• An optimum coil rotation angle exists for sheet contact with flat-bottomed die for each coil discharge position.
• 3D profilometry provided validation of numerical simulation.

In order to provide guidance to future forming of deep and large parts, 3D numerical simulation was used to study large sheet deformation process. We designed two different die structures to analyze forming process, during which the coil discharged successively at different positions. The value of material flowing, the effect of subsequent deformation on deformed sheet region, strain distribution and forming quality are all analyzed and discussed. We found flat-bottom die, two times discharging in one position, discharging voltage and coil rotation angle are key factors, which effect final forming quality directly.

Figure optionsDownload as PowerPoint slide