The Effect of a Field Shaper on Electromagnetic Forming of Aluminum Tubes
| Autor: | Backus, David |
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| Jazyk: | angličtina |
| Rok vydání: | 2013 |
| Předmět: | |
| Druh dokumentu: | Text |
| Popis: | Electromagnetic forming uses large currents and induced magnetic fields to deform and shape conductive materials. The process has been used since a specific method was patented in 1958 but research into the process has increased significantly in the past two decades primarily due to interest in joining dissimilar metals. This thesis attempts to increase knowledge related to the control and repeatability of the process through use of a field shaper and to begin work on forming non-circular cross section, particularly rectangular tubes common to the automotive industry. Preliminary work was done to create a reusable coil and standard working procedure. From that procedure a repeatability test demonstrated the total strain of the tube was consistent within 2% standard deviation. Confident in the repeatability of the data two field shapers were created and varied. The first field shaper varied the forming length that affected the tube from 1 to 2 inches. The second field shaper varied the forming gap between the field shaper and tube from .005 to .025 inches. Each field shaper was tested at three power levels from 8.8 to 10.4 kJ. Analysis demonstrated that forming length and gap are quadratic terms that can have a significant effect on the shape and total forming that occurs. Both terms also interacted with power indicating any design must be power specific. A simulation of the process was completed in order to better predict the effect of varying field shapers. The simulation was able to fit the data well but systematic errors were present and additional work is required to generally determine the mutual inductance from the coil to the field shaper. Testing of a square tube formed only by coil and a finite element model demonstrated that even forming of a square tube would require a significant corner to side force ratio and may not be feasible. Additional forming attempts with a field shaper and a steel mandrel for support were not able to completely form the corners to the same deformation as the sides. However the sides do have significant deformation that could be used to create joints. A mandrel that mimics the natural “X” shape created in forming could potentially support sufficient load to be used as a joint. |
| Databáze: | Networked Digital Library of Theses & Dissertations |
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