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| Influence of the Structure Parameters of the Flat Field Shaper on the Eddy Current Distribution and Magnetic Concentration Effect |
| Li Chengxiang, Shen Ting, Wu Hao, Zhou Yan, Mi Yan |
| State Key Laboratory of Power Transmission Equipment & System Security and New Technology Chongqing University Chongqing 400044 China |
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Abstract Electromagnetic pulse welding (EMPW) technology has broad application prospects in the field of dissimilar metal connecting. Field shaper is an important part in the EMPW system. However, there are few researches on the influence of the structure of flat plate field shaper on its wording efficiency by changing the distribution of eddy currents. Therefore, the relationship among the structural parameters, eddy current distribution and wording efficiency of field shaper was explored from the basic principle of field shaper.
The flat field shaper used with multi-turn coil was taken as the research object. The circuit-magnetic field coupling model of EMPW plates was established by COMSOL Multiphysics. Reflected the wording efficiency of the field shaper by calculating the maximum instantaneous magnetic flux density on the surface of the plate to be welded. The structural parameters that affected the effectiveness of the field shaper include height, upper and lower surface diameter, upper and lower hole diameter and gap angle α, The angle α were jointly determined by the upper and lower hole diameters. When the coil and sample to be welded were confirmed, the diameter of the upper and lower surfaces and the diameter of the lower hole were determined accordingly, which were 200 mm, 20 mm and 10 mm respectively according to the application scenarios of EMPW. When the diameter of the upper hole was 10 mm. The simulation result showed that as the height of the field shaper increased, the cancellation effect of the magnetic flux density generated by the induced eddy currents on the upper and lower surfaces of the field shaper gradually weakened, but the eddy current loss increased. So the working efficiency of field shaper first increased and then decreased with the increased of height, and it was the best at a height of 10 mm. There was bifurcation phenomenon of eddy current in the field shaper gaps, it could be divided into two parts: effective current and leakage current, and the effective current can be used for welding. The angle α had an important impact on the selection of the current path on the side of the gaps, which decided the proportion of effective current. The proportion of effective current continuously increased with the decrease of the angle α. When the height and lower hole diameter were both 10 mm, as the upper hole diameter increased, the total current decreased and the proportion of effective current continuously increased. So the efficiency of field shaper showed a trend of increasing first and then decreasing. When the upper hole diameter was better than that of lower hole, the angle α was an acute angle, the overall magnetic collection effect was better. And when α=45°, the efficiency of field shaper was the best.
To verified the simulation results, the EMPW platform suitable for copper plate and aluminum plate was established, and different structural field shaper (acute angle, right angle and obtuse angle) were made. Welding experiments, tensile test and peeling experiments were carried out. The results showed that the tensile strength of the sample increased with the increased of voltage. The copper-aluminum sample welded with a sharp angle field shaper got the highest tensile strength, the largest effective welding area and the best welding effect. The welding effect of the right angle field shaper was middle, and the obtuse angle field shaper was the worst.
The following conclusions can be drawn from the simulation and experiments: (1) As the height of the field shaper increases, the working efficiency fist increasing and then decreasing, and there is an optimal parameter for the height of the field shaper. (2) There was bifurcation phenomenon of eddy current in the field shaper gaps, and it’s divided into leakage current and effective current, the angle of field shaper gaps influence the current path selection and the ratio of effective current a lot. (3) As the upper hole diameter of field shaper increases, the total current decreases and the proportion of effective current continuously increases. Therefore, the field shaper effect shows a trend of increasing first and then decreasing.
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Received: 11 January 2022
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2023, Vol. 38 
