Coil-Less Electromagnetic Incremental Forming for Low-Conductivity Sheets
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Solution Overview
Problem
Traditional electromagnetic pulse forming processes are ineffective for low-conductivity materials like steel and titanium alloys due to insufficient electromagnetic forming force, and coil-less processes face high costs and complexity in forming large, complex parts.
Innovation Solution
A device combining coil-less electromagnetic pulse incremental forming with a three-axis moving frame, induction block, and discharging contactors to form low-conductivity materials, using incremental forming principles and localized energization to shape complex parts efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional electromagnetic pulse forming with coils is used, then high-conductivity materials like aluminum can be formed effectively, but low-conductivity materials like steel and titanium alloys cannot be formed due to insufficient electromagnetic forming force
Solution Approach 1:
The patent changes the physical parameters of the electromagnetic pulse forming system by replacing traditional coils with an induction block, operating at different frequencies (20-100 kHz), and using self-resistance heating to raise sheet temperature to 100-500°C. These parameter changes enable effective forming of low-conductivity materials like steel and titanium alloys that cannot be formed using traditional coil-based electromagnetic pulse forming.
2Adaptability or versatility
If coil-less electromagnetic pulse forming is used to process low-conductivity materials, then material compatibility is improved, but forming large and complex workpieces requires large and complex molds and induction plates resulting in long production cycles and high costs
Solution Approach 1:
The patent applies incremental forming by dividing the formation of large and complex workpieces into multiple small local deformations. The induction block and mold move incrementally across the sheet, applying localized electromagnetic pulses to form complex shapes through accumulated small deformations. This segmentation approach avoids the need for single large complex molds and induction plates, reducing production cycle time and cost.
Solution Approach 2:
The patent employs a dynamic incremental forming process where the induction block and mold move relative to the sheet in a controlled manner. The system dynamically adjusts the positioning and applies electromagnetic pulses sequentially at different locations, enabling flexible formation of complex geometries without requiring static large-scale equipment.
3Force
If self-resistance heating is used to soften low-conductivity materials, then forming force is reduced, but energy consumption increases
Solution Approach 1:
The patent uses periodic electromagnetic pulses for self-resistance heating, applying energy in repeated cycles rather than continuous heating. The induction block delivers pulsed electromagnetic energy at frequencies of 20-100 kHz, allowing the sheet to heat up through self-resistance while the intermittent nature of the pulses reduces overall energy consumption compared to continuous heating methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient formation of large and complex low-conductivity parts with reduced energy loss and cost, improving the lifespan and flexibility of induction blocks, and allowing for varied workpieces with simple mold changes.
Implementation Method 1
When a pulse current passes through the coils, a first electromagnetic field is generated, which induces a current in the sheet to be formed, thereby forming a second electromagnetic field. A repulsive force between the first and second electromagnetic fields causes the sheet to be formed to deform.
Implementation Method 2
A repulsive force between the first and second electromagnetic fields causes the sheet to be formed to deform.
Implementation Method 3
By using a self-resistance heating forming of the sheet, low-conductivity materials can be directly processed. By selecting appropriate voltage and current to heat the sheet according to the process requirements, the resistance heat generated can locally soften the material, reduce the yield strength, and decrease the forming force.
Data Source
AI summary
A device of coil-less electromagnetic pulse incremental forming for a metal sheet includes a lathe, a three-axis moving frame, a sheet clamping table, a mold, a discharging component, a power supply system, and a control cabinet. A worktable is disposed on a top of the lathe. The three-axis moving frame is disposed on a top of the worktable, and an induction block is disposed on the three-axis moving frame. A sheet to be formed is clamped on the sheet clamping table. The mold is mounted on a top surface of the worktable. The discharging component includes first discharging contactors and second discharging contactors. The power supply system is electrically connected to the first discharging contactors or the second discharging contactors. The device combines coil-less electromagnetic pulse forming and incremental forming processes, which can directly and efficiently form large and complex parts made of low-conductivity materials.