|
|
|
| Research on Flanging Method Driven by Synergistic Axial-Radial Bidirectional Electromagnetic Forces |
| Du Limeng1,2, Zhang Wang1,2, Zhu Xinhui1,2, Li Liang1,2, Cao Quanliang1,2 |
1. Wuhan National High Magnetic Field Center Huazhong University of Science and Technology Wuhan 430074 China;
2. School of Electrical and Electronic Engineering Huazhong University of Science and Technology Wuhan 430074 China |
|
|
|
Abstract Conventional uniaxial flanging processes for aluminum alloys face a fundamental trade-off: they achieve insufficient forming height at large flanging coefficients, while risking edge fracture at small coefficients. This limitation severely restricts their application in manufacturing high-performance, lightweight components. The underlying cause lies in the constrained material flow induced by uniaxial loading, which results in excessive thinning at the hole edge and makes it difficult to achieve both sufficient flanging height and good forming quality.
To address this challenge, this study proposes a novel electromagnetic-driven flanging method based on the synergistic excitation of dual coils, which generate axial and radial electromagnetic forces, respectively. The axial force provides the primary driving force for forming, while the radial force actively directs material from the flange into the die cavity. An electromagnetic-mechanical coupled model was established using LS-DYNA to simulate this bidirectional force-based flanging process. A corresponding experimental prototype with dual pulsed power supplies and dual coils was also developed, enabling a comparative investigation of electromagnetic-driven flanging under both uniaxial and axial-radial bidirectional configurations.
Comprehensive numerical simulations and experimental tests were conducted to evaluate the deformation behavior and flanging performance of AA5052-O aluminum alloy sheets with preformed holes. The results reveal that although the bidirectional process does not alter the stress-strain state at the hole edge, it effectively enhances material flow in the flange area, leading to a significant increase in wall height. Building on this finding, a novel forming strategy is proposed to improve the flanging limit: a larger flanging coefficient is selected to ensure edge quality, while radial electromagnetic force is introduced to enhance material flow into the flanging zone. This approach successfully resolves the inherent conflict in conventional uniaxialprocesses between achieving greater height and controlling edge thinning. The final results demonstrate that the proposed strategy achieves a 72.95% increase in flanging height at a flanging coefficient of 0.702 compared to uniaxial loading, and maintains a 31.04% improvement even against a uniaxial process with a lower coefficient of 0.602.
A mechanistic analysis further clarifies the influence of discharge voltage and timing for both coils on flanging performance. Appropriate discharge matching is key to leveraging electromagnetic synergy. Specifically, with a constant radial coil voltage, flange flow initially increases and then decreases as the axial coil voltage rises. When the axial coil voltage is held constant, flange flow increases with higher radial coil voltage. In terms of discharge timing, moderately advancing the radial coil discharge (by approximately 250 μs) under the experimental conditions helps utilize the complementary effects of radial electromagnetic force and punch-driven material flow across different stages. This enhanced material flow capability contributes to the increased flanging height.
Looking ahead, future work should further investigate the coupling mechanisms of blank-holder force, axial force, and radial force on flanging performance. Meanwhile, for local flanging applications on large flat or curved aluminum alloy sheets, focused research on axial-radial bidirectional electromagnetic force design and process parameter optimization is needed to advance this technology and its practical engineering applications.
|
|
Received: 03 July 2025
|
|
|
|
|
|
[1] Zheng Kailun, Politis D J, Wang Liliang, et al.A review on forming techniques for manufacturing lightweight complex: shaped aluminium panel components[J]. International Journal of Lightweight Materials and Manufacture, 2018, 1(2): 55-80.
[2] Dewang Y, Sharma V.Sheet metal shrink flanging process: a critical review of current scenario and future prospects[J]. Materials and Manufacturing Processes, 2023, 38(6): 629-658.
[3] Huang Youmin, Chien K H.The formability limitation of the hole-flanging process[J]. Journal of Materials Processing Technology, 2001, 117(1/2): 43-51.
[4] Marciniak Z, Duncan J L, Hu J.Mechanics of Sheet Metal Forming[M]. Oxford: Butterworth-Heinemann, 2002.
[5] Centeno G, Silva M B, Cristino V A M, et al. Hole-flanging by incremental sheet forming[J]. International Journal of Machine Tools and Manufacture, 2012, 59: 46-54.
[6] 熊奇, 阎诺, 邱爽, 等. 吸引力电磁成形上下同轴组合线圈受力分析[J]. 中国电机工程学报, 2025, 45(19): 7831-7841.
Xiong Qi, Yan Nuo, Qiu Shuang, et al.Force analysis of upper and lower coaxial combined coils for attractive electromagnetic forming[J]. Proceedings of the CSEE, 2025, 45(19): 7831-7841.
[7] Zhu Xinhui, Xu Xiaofei, Zhang Wang, et al.Electromagnetic shielding forming: a facile approach for Lorentz force regulation and its application in tube forming[J]. Journal of Materials Processing Technology, 2025, 338: 118795.
[8] 邱立, 余一杰, 聂小鹏, 等. 管件电磁胀形过程中的材料变形性能问题与电磁力加载方案[J]. 电工技术学报, 2019, 34(2): 212-218.
Qiu Li, Yu Yijie, Nie Xiaopeng, et al.Study on material deformation performance and electromagnetic force loading in electromagnetic tube expansion process[J]. Transactions of China Electrotechnical Society, 2019, 34(2): 212-218.
[9] Zhou Yan, Li Chengxiang, Shen Ting, et al.Interfacial microstructure of multi-layered Al-Cu joint by electromagnetic pulse welding[J]. Journal of Materials Research and Technology, 2023, 25: 2446-2454.
[10] Zhang Hang, Ding Hongfa, Li Xiaoxiang, et al.A new method of magnetic pulse welding of dissimilar metal plates using a uniform pressure electromagnetic actuator based on pre-deformation[J]. Scientific Reports, 2024, 14: 17226.
[11] 李成祥, 王现民, 周言, 等. 基于双线圈结构的铝-铜电磁脉冲板件焊接中间层抑制方法[J]. 电工技术学报, 2025, 40(13): 4112-4124.
Li Chengxiang, Wang Xianmin, Zhou Yan, et al.The suppression of intermediate layer in Al-Cu electromagnetic pulse welding with double coils structure[J]. Transactions of China Electrotechnical Society, 2025, 40(13): 4112-4124.
[12] 张文忠, 陈浩, 董占国, 等. 基于磁脉冲技术的铝合金板材圆孔翻边工艺研究[J]. 航天制造技术, 2009(4): 5-7, 16.
Zhang Wenzhong, Chen Hao, Dong Zhanguo, et al.Research on formability of aluminum alloy flanged hole by EMF[J]. Aerospace Manufacturing Technology, 2009(4): 5-7, 16.
[13] Yu Haiping, Zheng Qiuli, Wang Shoulong, et al.The deformation mechanism of circular hole flanging by magnetic pulse forming[J]. Journal of Materials Processing Technology, 2018, 257: 54-64.
[14] Zhang Lei, Cui Xiaohui, Deng Qiang, et al.Comparison of the deformation behavior of circular hole-flanging obtained by electromagnetic forming and stamping[J]. The International Journal of Advanced Manufacturing Technology, 2022, 121(1): 171-183.
[15] Zhang Xu, Huang Yunkai, Wang Yingyu, et al.Numerical simulation and experimental study on electromagnetic punching-flanging process of 6061 aluminum alloy sheets[J]. Journal of Manufacturing Processes, 2022, 84: 902-912.
[16] Wang Hanpeng, Yan Ziqin, Xiao Ang, et al.Improvement of flanging accuracy with small springback and service performance of AA7075 using high-speed forming[J]. Journal of Manufacturing Processes, 2024, 119: 790-805.
[17] 崔晓辉, 张磊, 陈浩, 等. 电磁斜孔翻边的板料结构设计和变形规律研究[J]. 锻压技术, 2023, 48(5): 168-175.
Cui Xiaohui, Zhang Lei, Chen Hao, et al.Research on sheet structural design and deformation law for electromagnetic oblique hole flanging[J]. Forging & Stamping Technology, 2023, 48(5): 168-175.
[18] 刘昊, 黄亮, 孙怡然, 等. 2024铝合金锥形孔电磁翻边线圈设计及成形工艺研究[J]. 中国机械工程, 2024, 35(12): 2149-2156.
Liu Hao, Huang Liang, Sun Yiran, et al.Research on coil design and forming processes of 2024 aluminum alloy conical hole electromagnetic flanging[J]. China Mechanical Engineering, 2024, 35(12): 2149-2156.
[19] Su Hongliang, Huang Liang, Li Jianjun, et al.Two-step electromagnetic forming: a new forming approach to local features of large-size sheet metal parts[J]. International Journal of Machine Tools and Manufacture, 2018, 124: 99-116.
[20] Li Meng, Lai Zhipeng, Xu Wei, et al.A versatile electromagnetic actuator for sheet and tube flanging: process principle, simulation, and experimental validation[J]. Journal of Manufacturing Processes, 2022, 81: 311-327.
[21] Cao Quanliang, Du Limeng, Li Zhenhao, et al.Investigation of the Lorentz-force-driven sheet metal stamping process for cylindrical cup forming[J]. Journal of Materials Processing Technology, 2019, 271: 532-541.
[22] Liu Wei, Wu Jinjie, Liu Jili, et al.Comparison of electromagnetic-driven stamping and electromagnetic forming limit curves for AA5182-O aluminum alloy sheet[J]. The International Journal of Advanced Manufacturing Technology, 2023, 126(5): 2567-2577.
[23] Ou Hang, Sun Shijin, Li Panfeng, et al.A dynamic small-sized hole flanging process driven by Lorentz-force for aluminum alloys[J]. International Journal of Material Forming, 2021, 14(5): 1019-1030.
[24] Cui Junjia, Sun Shijin, An Hao, et al.Effect of ironing on forming characteristics in the Lorentz-force-driven hole flanging process[J]. Journal of Materials Processing Technology, 2022, 301: 117442.
[25] Lai Zhipeng, Cao Quanliang, Zhang Bo, et al.Radial Lorentz force augmented deep drawing for large drawing ratio using a novel dual-coil electromagnetic forming system[J]. Journal of Materials Processing Technology, 2015, 222: 13-20.
[26] Fang Jinxiu, Mo Jianhua, Bai Fengmei, et al.Experimental investigations of the electromagnetic pulse-assisted incremental drawing of aluminum alloy[J]. The International Journal of Advanced Manufacturing Technology, 2019, 103(5): 2991-3001.
[27] Du Limeng, Zhang Wang, Ouyang Shaowei, et al.Advancing sheet metal stamping: the power of axial-radial Lorentz force synergistic forming[J]. Materials and Manufacturing Processes, 2025, 40(6): 796-805.
[28] Cao Quanliang, Han Xiaotao, Lai Zhipeng, et al.Analysis and reduction of coil temperature rise in electromagnetic forming[J]. Journal of Materials Processing Technology, 2015, 225: 185-194.
[29] Liu Dahai, Li Chunfeng, Yu Haiping.Numerical modeling and deformation analysis for electroma-gnetically assisted deep drawing of AA5052 sheet[J]. Transactions of Nonferrous Metals Society of China, 2009, 19(5): 1294-1302.
[30] Li Ning, Yu Haiping, Xu Zhu, et al.Electromagnetic forming facilitates the transition of deformation mechanism in 5052 aluminum alloy[J]. Materials Science and Engineering: A, 2016, 673: 222-232.
[31] 官英平. 圆孔翻边极限翻边系数计算方法探讨[J]. 模具技术, 2000(3): 58-60, 70.
Guan Yingping.Calculation method research on limited burring factor in round[J]. Die and Mould Technology, 2000(3): 58-60, 70. |
|
|
|
2026, Vol. 41 
