The Research Of EMF Finite Element Method And The Analysis Of The Coil Design

Lightweight is the tendency of auto industry today. Aluminum is an importantmeans to reduce vehicle weight, However, the traditional aluminum forming process is verydifficult, the electromagnetic forming(EMF) can solve the problem of forming aluminum.EMF is a high-intensity transient magnetic field on the use of metal sheet forming method,its forming rate is high, so EMF can improve the performance of metal forming, therebyimproving the strain distribution, reduce wrinkling and springback of the workpiece.Not only EMF theory relates to electrical, electromagnetic, plastic dynamics and someother disciplines, but also in the forming process, the electromagnetic process interactionswith the dynamic process of forming, these make that using analytical method isvery difficult to study EMF. Therefore, finite element numerical simulation has become animportant choice of researchers, and the full coupling method is the most accurate finiteelement method. In this paper, the full coupling method of EMF is developed by ANSYS.Compared with the experimental data, the accuracy of the simulation method is verified.This paper also has studied the discharge frequency of EMF, and gets the best frequency ofthe EMF system, improving the energy efficiency of EMF system.Coil is the core component of the EMF system, its main role is to conduct transientpulse current in order to induce the magnetic field on the sheet. The sheet and the coil repeleach other, which use the electromagnetic force to form the metal sheet. Therefore thecoil must have sufficient mechanical strength, the best frequency of discharge current andoptimal structural design. The paper analyzes the magnetic force distribution on the sheet,and the magnetic force and the failure modes of double coils are also analyzed, the paperoffers structure improvement suggestions and failure prevention methods. The paperdesigns a curved surface spiral coil and a curved uniform pressure electromagnetic actuator,analyzes the magnetic force distribution on the sheet, proposes the appropriate processtechnology by this two curved surface coils.