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| Dynamic Process Analysis and Optimization of Forming Effects in Lorentz Force Stamping for Polygonal Sheet Metal |
| Xiong Qi1,2, Chen Kaichuang1,3, Ma Chaojie1,3, Wang Yizhe1,3, Yan Nuo1,3 |
1. College of Electrical Engineering & New Energy China Three Gorges University Yichang 443002 China;
2. Wuhan National High Magnetic Field Center Huazhong University of Science and Technology Wuhan 430074 China;
3. Hubei Provincial Engineering Research Center of Intelligent Energy Technology China Three Gorges University Yichang 443002 China |
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Abstract Comparison with the conventional quasi-static stamping technology, the utilization of Lorentz force-driven stamping technology has the potential to significantly enhance the forming limit of sheet metal. Nevertheless, the extant research merely corroborated the viability of this approach, yet did not investigate the ultimate forming quality, which is challenging to align with the diverse requirements of the industry. Consequently, a Lorentz force stamping scheme for polygonal sheet metal is put forth in this paper. A finite element model is constructed to examine the dynamic process and forming effect, and the forming effect is optimized.
Firstly, the basic model of the stamping system is established, and the most important parts of the system driver and punch are designed, and the circuit with continuous flow circuit is used to generate repulsive force to drive the forming. Secondly, because the forming process is very fast, a simulation model must le established to study the forming dynamic process and the final forming effect in detail. Finally, a fully coupled electromagnetic and mechanical field model is established to verify the feasibility of the proposed scheme.
The simulation results demonstrate that the forming process of this scheme can be divided into three distinct stages: the acceleration stage, the inertia stage, and the rebound stage. The maximum forming depth achieved was 35.00 mm, with the plate exhibiting smooth sticking. The equivalent strain level was low, with a maximum thinning rate of 20.13%. The shaped plate exhibited an effective forming effect. The maximum thinning rate was optimized by manipulating the holding force, friction coefficient and discharge voltage. The maximum thinning rate was reduced to 8.31% under the optimal parameter combination.
The conclusions are as follows: (1) The scheme is capable of forming polygonal sheet metal at a significantly higher speed than the traditional quasi-static forming method, while also enhancing the forming limits of sheet metal. The final forming effect is satisfactory. (2) The method exhibits characteristics of both electromagnetic forming and traditional quasi-static forming. The forming process is completed within 2.50 ms, which is a relatively short time. The forming dynamic process is divided into three stages according to the speed change of the driving device: accelerating dynamic stage, inertia stage and rebound stage. The principal forming stage is the inertial movement stage, which ensures the subsequent forming effect. (3) The friction coefficient, the blank holding force, and the discharge voltage have been selected to further optimize the maximum thinning rate. Following the optimization process, the optimal parameter combination was identified as a friction coefficient of 0.171, a blank holding force of 81.95 kN, and a discharge voltage of 11.74 kV for the drive circuit. At this juncture, the maximum thinning rate of the plate is 8.31%, which represents a 58.71% increase over the preceding baseline.
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Received: 08 April 2024
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2025, Vol. 40 
