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| Research on Electromagnetic Force Distribution and Axial Uniformity of Tube Electromagnetic Bulging Based on Discrete Shielding |
| Qiu Li1,2, Chen Yuhong1,2, Zhang Jinrong1,2, Li Mengyao1,2, Jiang Jinbo1,2 |
1. College of Electrical Engineering and New Energy China Three Gorges University Yichang 443002 China;
2. Hubei Provincial Key Laboratory for Operation and Control of Cascaded Hydropower Station Yichang 443002 China |
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Abstract In the processing of lightweight metallic materials, electromagnetic forming technology offers significant advantages over traditional mechanical processing methods. It provides a new technical approach for achieving “carbon peak and carbon neutrality” in industries such as aerospace and automotive. However, the traditional tube electromagnetic bulging suffers from issues such as axial deformation inhomogeneity due to the end effect. To address the technical deficiencies in traditional tube electromagnetic bulging, a new method based on discrete shielding is proposed to improve the distribution of electromagnetic force on the tube.
The principle of tube electromagnetic bulging based on discrete shielding is as follows: discrete shielding rings are introduced between the driving coil and the tube component. The tube is acted upon by both the original driving coil and the discrete shielding rings, which reduces the induced eddy current density and radial electromagnetic force density in the central region of the tube. This causes the radial electromagnetic force distribution during the tube's electromagnetic bulging to change from the traditional “convex” shape to a “concave” shape. To verify the effectiveness of the discrete shielding-based method, a coupled finite element model incorporating the electrical, electromagnetic, and structural aspects of the tube electromagnetic bulging was established using COMSOL simulation software. The study investigates the effects of key parameters, such as the number of discrete shielding rings, the total height of the shielding rings, and the relative axial distance between the rings, on the radial electromagnetic force distribution and radial displacement of the tube. Additionally, comparative studies are conducted on the radial electromagnetic force distribution, radial displacement, and final forming profile of tube components under traditional electromagnetic bulging, single-shielded electromagnetic bulging, and discrete shielding-based electromagnetic bulging.
Simulation results indicate that as the number of discrete shielding rings increases, the deformation profile of the tube changes from “concave” to “convex”. As the total height of the shielding rings increases, the profile shifts from “convex” to “concave”. With an increase in the relative axial distance between the shielding rings, the profile transitions from “concave” to “convex”. For specific tube components to be processed, there exists an optimal set of structural parameters for the discrete shielding rings. When the number of shielding rings is five, the total height is 6 mm, and the relative axial distance is 3 mm, the tube's electromagnetic bulging exhibits the best uniformity. In terms of axial uniform deformation, traditional electromagnetic bulging, single-shielded electromagnetic bulging, and discrete shielding-based electromagnetic bulging yield axial uniform regions of 12.50 mm, 14.20 mm, and 31.25 mm, respectively, when the maximum bulging amount is the same. Compared with the traditional tube electromagnetic bulging, the axial uniform area of tube electromagnetic bulging based on discrete shielding is increased by 1.5 times. Clearly, the introduction of discrete shielding rings effectively weakens the induced eddy currents and radial electromagnetic forces in the central region of the tube, ultimately enhancing the axial uniformity of tube electromagnetic bulging. The practical effectiveness of this forming method will be further validated through future experimental work.
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Received: 25 October 2024
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2025, Vol. 40 
