Electromagnetic forming process analysis based on coupled simulations of electromagnetic analysis and structural analysis

Abstract

We conducted a phased electromagnetic forming process analysis (EFPA) over time through a coupling of electromagnetic analysis and structural analysis. The analysis is conducted through a direct linkage between electromagnetic analysis and structural analysis. The analysis process is repeated until the electric current is completely discharged by a formed coil. We calculate the forming force that affects the workpiece using MAXWELL, a commercial electromagnetic finite element analysis program. Then, we simulate plastic behavior by using the calculated forming force data as the forming force input to ANSYS, a commercial structure finite element analysis program. We calculate the forming force data by using the model shape in MAXWELL, a commercial electromagnetic finite element analysis program. We repeat the process until the current is fully discharged by the formed coil. Our results can be used to reduce the error in data transformation with a reduced number of data transformations, because the proposed approach directly links the electromagnetic analysis and the structural analysis after removing the step of the numerical analysis of a graph describing the forming force, unlike the existing electromagnetic forming process. Second, it is possible to simulate a more realistic forming force by keeping a certain distance between nodes using the re-mesh function during the repeated analysis until the current is completely discharged by the formed coil, based on the MAXWELL results. We compare and review the results of the EFPA using the peak value of the forming force that acts on the workpiece (which is the existing analysis method), and the proposed phased EFPA over time approach.