Dynamic Analysis of Closed Die Electromagnetic Sheet Metal Forming to Predict Deformation and Failure of AA6061-T6 Alloy Using a Fully Coupled Finite Element Model
This research presents a fully coupled 3D numerical model to analyse the dynamics of high-speed electromagnetic forming process for aluminium alloy AA6061-T6. The effect of Lorentz force distribution, velocity and kinetic energy on deformation, the bounce back effect and failure of the sheet has bee...
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| Format: | Article |
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MDPI AG
2022-11-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/15/22/7997 |
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| author | Zarak Khan Mushtaq Khan Se-Jin Yook Ashfaq Khan Muhammad Younas Muhammad Zeeshan Zahir Muhammad Asad |
| author_facet | Zarak Khan Mushtaq Khan Se-Jin Yook Ashfaq Khan Muhammad Younas Muhammad Zeeshan Zahir Muhammad Asad |
| author_sort | Zarak Khan |
| collection | DOAJ |
| description | This research presents a fully coupled 3D numerical model to analyse the dynamics of high-speed electromagnetic forming process for aluminium alloy AA6061-T6. The effect of Lorentz force distribution, velocity and kinetic energy on deformation, the bounce back effect and failure of the sheet has been investigated. Experiments were performed for AA6061-T6 alloy using an 18.750 KJ electromagnetic forming machine for varying the sheet thickness (0.5 mm, 1.02 mm and 1.63 mm) compared with the simulation results. The results showed that increasing the sheet thickness increases the Lorentz force due to a higher induced current. The inertial forces were more pronounced in thicker sheets (1.63 mm) as compared to the thinner sheets (0.5 mm and 1.02 mm), resulting in a higher bounce back effect for the thicker sheet. The numerical model accurately predicted the sheet failure for the 0.5-mm sheet, as also observed from the experimentation. The sheet deformation from simulations was found to be in good agreement with the experimental results. |
| first_indexed | 2024-03-09T18:11:58Z |
| format | Article |
| id | doaj.art-9a6bd59f00994a9c84575fa3ca66db38 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-09T18:11:58Z |
| publishDate | 2022-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-9a6bd59f00994a9c84575fa3ca66db382023-11-24T09:02:28ZengMDPI AGMaterials1996-19442022-11-011522799710.3390/ma15227997Dynamic Analysis of Closed Die Electromagnetic Sheet Metal Forming to Predict Deformation and Failure of AA6061-T6 Alloy Using a Fully Coupled Finite Element ModelZarak Khan0Mushtaq Khan1Se-Jin Yook2Ashfaq Khan3Muhammad Younas4Muhammad Zeeshan Zahir5Muhammad Asad6Department of Mechanical Engineering, HITEC University, Taxila 47080, PakistanMechanical Engineering Department, Prince Mohammad Bin Fahd University, Al-Khobar 31952, Saudi ArabiaSchool of Mechanical Engineering, Hanyang University, Seoul 04763, KoreaSchool of Engineering, Robert Gordon University, Aberdeen AB10 7GJ, UKSchool of Engineering, Robert Gordon University, Aberdeen AB10 7GJ, UKDepartment of Mechanical Engineering, University of Engineering and Technology, Peshawar 25000, PakistanMechanical Engineering Department, Prince Mohammad Bin Fahd University, Al-Khobar 31952, Saudi ArabiaThis research presents a fully coupled 3D numerical model to analyse the dynamics of high-speed electromagnetic forming process for aluminium alloy AA6061-T6. The effect of Lorentz force distribution, velocity and kinetic energy on deformation, the bounce back effect and failure of the sheet has been investigated. Experiments were performed for AA6061-T6 alloy using an 18.750 KJ electromagnetic forming machine for varying the sheet thickness (0.5 mm, 1.02 mm and 1.63 mm) compared with the simulation results. The results showed that increasing the sheet thickness increases the Lorentz force due to a higher induced current. The inertial forces were more pronounced in thicker sheets (1.63 mm) as compared to the thinner sheets (0.5 mm and 1.02 mm), resulting in a higher bounce back effect for the thicker sheet. The numerical model accurately predicted the sheet failure for the 0.5-mm sheet, as also observed from the experimentation. The sheet deformation from simulations was found to be in good agreement with the experimental results.https://www.mdpi.com/1996-1944/15/22/7997electromagnetic formingLorentz forcedeformationdynamic analysis |
| spellingShingle | Zarak Khan Mushtaq Khan Se-Jin Yook Ashfaq Khan Muhammad Younas Muhammad Zeeshan Zahir Muhammad Asad Dynamic Analysis of Closed Die Electromagnetic Sheet Metal Forming to Predict Deformation and Failure of AA6061-T6 Alloy Using a Fully Coupled Finite Element Model Materials electromagnetic forming Lorentz force deformation dynamic analysis |
| title | Dynamic Analysis of Closed Die Electromagnetic Sheet Metal Forming to Predict Deformation and Failure of AA6061-T6 Alloy Using a Fully Coupled Finite Element Model |
| title_full | Dynamic Analysis of Closed Die Electromagnetic Sheet Metal Forming to Predict Deformation and Failure of AA6061-T6 Alloy Using a Fully Coupled Finite Element Model |
| title_fullStr | Dynamic Analysis of Closed Die Electromagnetic Sheet Metal Forming to Predict Deformation and Failure of AA6061-T6 Alloy Using a Fully Coupled Finite Element Model |
| title_full_unstemmed | Dynamic Analysis of Closed Die Electromagnetic Sheet Metal Forming to Predict Deformation and Failure of AA6061-T6 Alloy Using a Fully Coupled Finite Element Model |
| title_short | Dynamic Analysis of Closed Die Electromagnetic Sheet Metal Forming to Predict Deformation and Failure of AA6061-T6 Alloy Using a Fully Coupled Finite Element Model |
| title_sort | dynamic analysis of closed die electromagnetic sheet metal forming to predict deformation and failure of aa6061 t6 alloy using a fully coupled finite element model |
| topic | electromagnetic forming Lorentz force deformation dynamic analysis |
| url | https://www.mdpi.com/1996-1944/15/22/7997 |
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