Finite-Element Simulation and Experiments on Plastic Heating in the Process of Electromagnetic Pulse Forming

Electromagnetic pulse forming (EMPF) is an attractive manufacturing method using pulse power techniques. Temperature rise of the work piece is usually neglected in previous studies because the forming process is regarded as a cold process. Nevertheless, the temperature rise (if not high) also has influence on the forming process. It is important to study the temperature rise for exploring the related law in the process of EMPF. In this paper, the thermal effect in the process of EMPF, caused by the joule heating generated by the high current and the plastic work produced by the plastic deformation of the work piece in the forming process, is discussed though simulations and experiments. A finite-element simulation coupled with the electromagnetic field, plastic mechanics, deformed geometry, heat transfer, and thermal expansion based on COMSOL multiphysics is established to show the detailed thermal effect in this process. The relationship between parameters of work piece and the thermal effect has been analyzed by comparing different materials and thicknesses of work pieces. The simulation results show that the temperature of work piece has changed because of the thermal effect. A high-current pulse generator has been developed for the experiment of EMPF to verify the results of simulations. This paper describes the forming experiments of different materials and thicknesses. And the experimental results verify that the materials and thickness of work piece affect thermal effect during the process of EMPF. Compared with the Joule heating, the plastic work is the main cause of the thermal effect. Moreover, the thermal expansion caused by temperature rise could affect the forming results and material property.