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Abstract

To make the advantages of electromagnetic forming applicable for industrial manufacturing, a three step tool design strategy is suggested. At first, simplified decoupled electromagnetic and structural mechanical simulations are used for creating a preliminary design via a systematic iterative optimization process. The selected design is verified in more accurate coupled simulations. A prototypic realization serves for further optimization, if necessary. The applicability of the approach is proved on the basis of an inductor system for magnetic pulse welding of tubes.

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... Despite these advantages, there are still restraints using this technology in industrial environments (Golovashchenko, 2006). According toNeugebauer et al. (2014), insufficient knowledge about the design of durable and likewise efficient working coils is one of the main reasons for this. The efficiency of the electromagnetic forming process Á is defined by the ratio of plastic strain energy E F to the initial charging energy of the pulse generator E C (Daube and Mattke, 1968). ...
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... A numerical simulation of the hydroforming process has shown that the joint has to withstand a maximum shear force of approximately 42 kN [5] In the next step an appropriate inductor system consisting of a suitable tool coil and a fieldshaper was designed for the magnetic pulse welding process (see Fig. 1a). For dimensioning this tool a methodology efficiently combining simplified decoupled and more accurate coupled electromagnetic and structural mechanical simulations was used [6,7]. The inductor system was realised by Poynting GmbH (Germany) and applied at IWU for producing hybrid tubes depicted in Fig. 1 ...
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The magnetic pulse welding (MPW) is a cold weld process of conductive metals to the similar or dissimilar material. MPW uses magnetic pressure to drive the primary metal against the target metal sweeping away surface contaminants while forcing intimate metal-to-metal contact, thereby producing a solid-state weld. In this paper the MPW method and its application for several aluminium alloy (A1050, A2017, A3004, A5182, A5052, A6016, and A7075) and steel (SPCC) sheets joint were investigated and the process parameters and welding characteristics are reported.
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