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Dynamic analysis of closed die electromagnetic sheet metal forming to predict deformation and failure of AA6061-T6 alloy using a fully coupled finite element model.

Khan, Zarak; Khan, Mushtaq; Yook, Se-Jin; Khan, Ashfaq; Younas, Muhammad; Zahir, Muhammad Zeeshan; Asad, Muhammad

Authors

Zarak Khan

Mushtaq Khan

Se-Jin Yook

Ashfaq Khan

Muhammad Zeeshan Zahir

Muhammad Asad



Abstract

This research presents a fully coupled 3D numerical model to analyse the dynamics of high-speed electromagnetic forming process for aluminium alloy AA6061-T6. The effect of Lorentz force distribution, velocity and kinetic energy on deformation, the bounce back effect and failure of the sheet has been investigated. Experiments were performed for AA6061-T6 alloy using an 18.750 KJ electromagnetic forming machine for varying the sheet thickness (0.5 mm, 1.02 mm and 1.63 mm) compared with the simulation results. The results showed that increasing the sheet thickness increases the Lorentz force due to a higher induced current. The inertial forces were more pronounced in thicker sheets (1.63 mm) as compared to the thinner sheets (0.5 mm and 1.02 mm), resulting in a higher bounce back effect for the thicker sheet. The numerical model accurately predicted the sheet failure for the 0.5-mm sheet, as also observed from the experimentation. The sheet deformation from simulations was found to be in good agreement with the experimental results.

Citation

KHAN, Z., KHAN, M., YOOK, S.-J., KHAN, A., YOUNAS, M., ZAHIR, M.Z. and ASAD, M. 2022. Dynamic analysis of closed die electromagnetic sheet metal forming to predict deformation and failure of AA6061-T6 alloy using a fully coupled finite element model. Materials [online], 15(22), article 7997. Available from: https://doi.org/10.3390/ma15227997

Journal Article Type Article
Acceptance Date Nov 8, 2022
Online Publication Date Nov 12, 2022
Publication Date Nov 30, 2022
Deposit Date Nov 21, 2022
Publicly Available Date Dec 8, 2022
Journal Materials
Electronic ISSN 1996-1944
Publisher MDPI
Peer Reviewed Peer Reviewed
Volume 15
Issue 22
Article Number 7997
DOI https://doi.org/10.3390/ma15227997
Keywords Electromagnetic forming; Lorentz force; Deformation; Dynamic analysis
Public URL https://rgu-repository.worktribe.com/output/1812927

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