Numerical Simulation Study of a Conical Magnetizer-Based Tube Electromagnetic Expansion Device

Traditional steel structures in the aerospace industry are transitioning towards lighter alloy materials as a result of rapid technological advancements. However, the conventional methods used for forming lightweight alloy pipes are faced with challenges in achieving more refined processing. To overcome these challenges, Electromagnetic Forming (EMF) has emerged as a viable solution. EMF utilizes pulsed electromagnetic forces to drive the forming process, offering advantages such as high forming speed and strain rate. Therefore, it is well-suited for the processing of alloy pipe components. In this research paper, we present a simulation study conducted using COMSOL to analyze the electromagnetic expansion device of conical flux collectors, which is applied to tube shaping. To explore and compare the characteristics of magnetic flux density distribution and radial deformation, we employ the electromagnetic-structural field coupling method for three different aluminum alloy materials, focusing on the heights of their inner and outer walls in the flux collector. The obtained results indicate that minimal differences exist in magnetic flux density distribution among the aluminum alloy materials, regardless of the height differences between the inner and outer walls. However, when it comes to radial deformation, the 6063 aluminum alloy exhibits the highest value, reaching up to 1.943mm.