Research on Composite Electromagnetic Forming of Aluminum Alloy Hollow Plate
Xiong Qi1,2, Lu Kai1,3, Cheng Hui2, Wei Yuying1,3, YanNuo1,3
1. College of Electrical Engineering & New Energy China Three Gorges University Yichang 443002 China; 2. Guangdong Provincial Key Laboratory of Extreme Conditions Dongguan 523803 China; 3. Hubei Provincial Engineering Research Center of Intelligent Energy Technology China Three Gorges University Yichang 443002 China
Abstract：As a high-speed forming technology that uses the Lorentz force to induce plastic deformation of metal materials, electromagnetic forming can effectively address the problems of uneven wall thickness, long manufacturing cycles, and complex processes caused by the superplastic forming/diffusion bonding process for manufacturing hollow plates. Therefore, this paper proposes a composite electromagnetic forming scheme for an aluminum alloy hollow plate. The principles of this technology are introduced. The process is divided into two key stages: hollow-cavity bulging and electromagnetic-pulse welding at both ends of the plate. First, the basic model of the electromagnetic forming system for hollow plate parts is established, and power supply systems for the through-flow forming and electromagnetic pulse welding processes are designed. Secondly, since the forming process is very rapid and it is difficult to observe changes in electromagnetic parameters, it is necessary to develop a simulation model to study the dynamic forming process. Finally, a fully coupled electromagnetic field and mechanics model is established, and the feasibility of the scheme is verified. The simulation results show that the cross-flow forming process can be divided into three stages: stress, inertia, and rebound. The inertia stage accounts for 70% of the total time of the cross-flow forming, and the cavity height is 20.1 mm. The electromagnetic pulse welding process connects the upper and lower plates at both ends, with a collision speed of 255.35 m/s and a collision angle of 11.31°. The conclusions are as follows. (1) Electromagnetic forming technology is used to form an aluminum alloy hollow plate with a 20.1 mm hollow cavity height, and the two ends of the plate are welded to form effective joints. The total processing time of the aluminum alloy hollow plate is less than 3 ms. Compared with the 2.5 h processing time required by the SPF/DB process, this scheme effectively leverages the material properties of aluminum alloy, such as high strain rate and high conductivity. It improves the manufacturing efficiency of aluminum alloy hollow plates. (2) Hollow cavity wall thickness’s size maximum tolerance is only 0.15 mm, and no appearance defects, meeting the 6063 aluminum alloy profile executive standard GB/T 5237—2008. Changing the plate thickness significantly affects forming uniformity. (3) By adjusting the system parameters, the forming height of the hollow cavity can be improved. Increasing the discharge voltage and discharge capacitance can significantly improve the forming height of the hollow cavity. On the contrary, increasing the thickness of the insulation plate and the plate significantly reduces the forming height of the hollow cavity.
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2026, Vol. 41 
