Finete Element Analysis On Electromagnetic Bulging With Die Of Aluminum Curevd Surface Parts

Focused on sustainable development, resource conservation and reduce environmental pollution have became two big problems for the world automotive industry to be solved.10% of each vehicle weight, fuel consumption can be reduced by 6% to 8%. Therefore, reducing vehicle weight is one of the most basic ways to save energy and improve fuel economy. Vehicle lighting is becoming the forefront and hot spots of automotive technology of 21st century. One of the main way for body lightweight is to choose new materials which have higher strength and lighter weight,such as aluminum, high-strength steel, etc. Aluminum has the advantages of resource-rich, low density, high strength, pressure casting process and good processing, recycling efficiency,which is considered to be the richest potential for development and application of "green materials " of the 21st century. Many automobile manufacturers seem it as a focus of study and the ideal material to reduce quality. However, the aluminum has poor formability and low stiffness at room temperature, using ordinary stamping process prone to tear, serious rebound and distortion occurred after unloading. It is difficult to meet the precision requirements of the parts.Electromagnetic forming technology is a high-energy rate forming, which generates a strong pulsed magnetic field by a high-voltage energy storage capacitor discharge instantaneously through the coil, the billets forming high-speedly under the impact of electromagnetic force. Compared with other high-energy rate forming, It has a series of advantages such as production efficiency, process repeatability and simple tooling, which can be used for aviation, aerospace, automobile manufacturing and other fields.It has much attention to the plastic processing industry.To use the electromagnetic technology for aluminum forming,it can improve the forming limit of aluminum alloy, improve the resilience, achieve the car lightweight and energy-saving on the one hand; It can greatly improve production efficiency on the other hand. Therefore,it is of great significance to research the electromagnetic forming of aluminum alloy in the actual production. In this paper, the distribution of magnetic forces of uniform pressure coil and the electromagnetic bulging with die of aluminum alloy 1060 surface parts will be researched useing the finite element method.The results show that:Uniform pressure coil can produce a uniform magnetic pressure on the sheet;The springback after electromagnetic aimed stamping is smaller than the springback afte normal stamping; Before achieving the best results, with the discharge energy increases, springback will be smaller; with greater punch and die clearance, greater energy will be needed to achieve the best effect; Too large discharge energy will lead sheet bounce after punch, springback increases. The simulation results correspond to the experimental results, it is of guiding significance on mold designing and parameter optimization on industrial production.