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

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