Electromagnetic forming and powder processing: Trends and developments

[+] Author and Article Information
AG Mamalis, DE Manolakos

Manufacturing Technology Division, National Technical University of Athens, Iroon Polytechneiou str 9, Zografou Campus, 15780, Athens, Greecemamalis@central.ntua.gr, manolako@central.ntua.gr

AG Kladas

Electric Power Division, National Technical University of Athens, Iroon Polytechneiou str 9, Zografou Campus, 15780, Athens, Greecekladasel@central.ntua.gr

AK Koumoutsos

Manufacturing Technology Division, National Technical University of Athens, Iroon Polytechneiou str 9, Zografou Campus, 15780, Athens, Greeceankoum@central.ntua.gr

Appl. Mech. Rev 57(4), 299-324 (Oct 12, 2004) (26 pages) doi:10.1115/1.1760766 History: Online October 12, 2004
Copyright © 2004 by ASME
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A fluid flow constrictor formed from a flat annular disk by the use of a pancake coil. 10kJ energy was stored in the capacitor bank 4
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a) A car door panel made of steel, indicating the area, where electromagnetic forming is needed, in case that the door material is substituted by Al 6111-T4. b) A two-turn flat coil for the electromagnetic precision local forming of the metal sheet. c) The electromagnetically formed area of the part 57
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a) Schematic of the MPW equipment, b) Geometrical parameters of the workpieces 114
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Cross-section of inductor, cladding tube, and helium manifold illustrating the position of the cladding tube inside the inductor and the position of the rod inside the cladding tube. The helium purge prevents surface degradation by atmospheric gases 111
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A typical microstructure of the MPW interface region 118
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A typical microhardness profile across the MPW interface 114
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Powder material consolidation using the DMC process 123
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a) Schematic diagram of the axisymmetric DMC configuration: 1: silver tube (∅12/∅10), 2: YBCO powder, 3: silver powder, 4: plastic disk, 5: steel bolt M5, 135b) An optical micrograph showing the microstructure of the metal sheathed superconductor material
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A schematic diagram of the electro-discharge compaction process 146
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Applications of the electromagnetic compression process for tube sealing. The upper section of each scheme represents the initial part assembly before forming, while the lower one represents the final joint configuration after forming 2
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Forming and piercing a tubular part in one operation. The energy stored in the capacitor bank was 6 kJ 4
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A schematic diagram of the device for uniaxial dynamic compaction of powders 143
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Principle of electromagnetic forming 19
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Inductor system element for the electromagnetic dielectric stamping: the plane dielectric workpiece on the ideal conducting metal surface 21
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Principle of electromagnetic tube compression with an outer coil 27
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Principle of electromagnetic tube expansion with an inner coil 27
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a) Principle of electromagnetic sheet metal forming with a pancake coil 27, b) The magnetic field around the pancake coil during the EMF process 28
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a) A three bar coil and b) the sheet metal workpiece. The sheet must be placed opposite the coil during forming 29
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Construction scheme and operating principle of a compression coil with field shaper 2
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The compression coil with a field shaper, which is installed in the Laboratory of the Manufacturing Technology of the NTUA 34
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Schematic diagram of a typical EMF process using a conductive driver 21, 1: coil, 2: conductive driver, 3: transmitting environment (rubber insert), 4: tubular workpiece (bad electrical conductor), 5: mandrel
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Electromagnetic forming process equivalent circuit
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Current in the forming coil and eddy current in the workpiece neglecting their phase shift
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Magnetic pressure pulse vs time
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a) Forces acting on an element of a compressed cylindrical workpiece, b) A detail to a
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Calculated curves of total elongation vs deformation velocity for both uniaxial tension and ring expansion 96
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Maximum circumferential strain before fracture vs ring height, in electromagnetic ring expansion 99
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Schematic diagram of traditional (left) and inertial ironing 99
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Forming limit diagram (FLD) of AA6061 in the case of both low and high rate forming 87
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Torque joint electromagnetically formed to assemble drive shaft for a passenger car to a universal-joint yoke. The joint can be both axially and torsionally loaded due to the circumferential groove (section A-A) and longitudinal pockets (section B-B), respectively 26
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An axially loaded joint fabricated by electromagnetic compression of an aluminum tube onto a grooved fitting



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