Performance Analysis of Electromagnetic Forming Process E-Book

Ronak Khandelwal

• Herausgeber: GRIN Verlag
• Sprache: Englisch

Veröffentlichungsjahr: 2015

Beschreibung

Master's Thesis from the year 2014 in the subject Engineering - Mechanical Engineering, grade: -, , course: Electromagnetic Forming Process, language: English, abstract: Electromagnetic Forming Process (EMF) is advanced high velocity metal forming process which deals with the application of high energy magnetic surge for very short duration of time in order to attain desired deformation. In this work, simulation of EMF process for tube bulging is performed and experimental validation is carried out. For simulation, COMSOL Multiphysics software is used. Simulation is performed for two material, aluminium 6063-O and copper. The results of simulation are validated by experiments on aluminum tube.

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ACKNOWLEDGEMENT

I take this opportunity to express my sincere gratitude towards Prof. Dr. Uday A. Dabade, Department of Mechanical Engineering, for his guidance and assistance provided during every stage of dissertation work. I am deeply obliged to him for extending his valuable direction and moral support which enabled me, for the completion of the dissertation work. His worthy inputs and co-operative nature during the period of the present study would remain inspirational to me throughout my life.

I am also grateful to Prof. Dr. B. S. Gawali, Head, Department of Mechanical Engineering, for extending support to complete the dissertation work successfully.

We are thankful to Mr. Z. H. Sholapurwala, Zeonics Systech Defence and Aerospace Engineers (P) Ltd., Bangalore for allowing us to carry out the experimental work.

I would like to appreciate the precious advice from other faculty members of Department of Mechanical Engineering, Walchand College of Engineering, Sangli, during every stage of the dissertation project.

I would like to sincerely thank Institute’s Library and Central Computing Facility for providing help during the dissertation work.

I express my genuine and special thanks to Shri V. Y. Jadhav, Shri S. G. Shivgan, Shri S. S. Sutar, Shri S. S. Kalel, Shri L. L. Kamble and other non-teaching staff of Department of Mechanical Engineering for their precious help during the course of dissertation work.

Last but not least I would like to thank parents, family and friends for endless support, encouragement and inspiration they provided to me throughout the period of the dissertation project.

ABSTRACT

Electromagnetic Forming Process (EMF) is advanced high velocity metal forming process which deals with the application of high energy magnetic surge for very short duration of time in order to attain desired deformation. The EMF process deals with high strain rate and velocity. The EMF process is a very versatile process capable of forming hard materials such as titanium alloys. However the application of EMF process is limited to only electrically conductive materials. In EMF process, high energy (current) is discharged from the capacitor bank through the solenoid coil with conductive workpiece placed in the vicinity of the coil; due to the discharge energy primary and secondary alternating magnetic field are developed resulting in generation of electromagnetic (Lorentz) force, responsible for the deformation of workpiece. The EMF process is applied for various applications such as tube bulging (or tube expansion), tube compression and sheet metal forming. EMF process yields many benefits over conventional process such as an excellent surface finish, high repeatability, negligible springback, high flexibility, etc. However, EMF process is also characterized by few disadvantages like the use of conductive material, high safety issues, low overall efficiency, etc. In this work, simulation of EMF process for tube bulging is performed and experimental validation is carried out. For simulation, COMSOL Multiphysics software is used. Simulation is performed for two material, aluminium 6063-O and copper. The results of simulation are validated by experiments on aluminum tube. The solenoid copper coil is designed and fabricated as per requirement. Using Taguchi Method, design of experiments is performed and L8 orthogonal array is used for simulation and experimentation purpose with three parameters, discharge energy (current), stand-off distance (gap between the coil and the workpiece) and workpiece thickness; four levels of discharge energy and two levels each of stand-off distance and workpiece thickness is used. ANOVA technique is used for analysis of deformation. AOM plots for the same are plotted using MINITAB 16 software. The results indicate that discharge energy is the most significant parameter followed by stand-off distance, whereas workpiece thickness is not significant parameter. Maximum deformation is attained for a combination of 2 kJ energies, 1 mm stand-off and 0.8 mm thickness, whereas minimum deformation is obtained for combination of 1.25 kJ energy, 1.5 mm stand-off and 0.8 mm thickness in simulation and experimental validation.

Keywords:EMF, COMSOL, Taguchi Method, Lorentz Force, AOM plot, stand-off distance, springback.

INDEX

LIST OF FIGURES

LIST OF TABLES

CHAPTER 1 INTRODUCTION

1.1 Introduction

1.2 Working

1.3 Advantages

1.4 Disadvantages

1.5 OBJECTIVES

1.6 Methodology

CHAPTER 2 LITERATURE REVIEW

2.1 Literature Review

2.2 Physics Governing EMF Process

CHAPTER 3 MODELING AND SIMULATION

3.1 Software used for Simulation

3.2 Material Selection

3.3 Coil

3.4 Process Parameters

3.5 Response Variable

3.6 Simulation of Experiments

CHAPTER 4 EXPERIMENTAL WORK, RESULTS AND ANALYSIS