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Electromagnetic forming is a novel technology in which a coil is used to generate a pulsed Lorentz force for shaping sheet metal pieces. However, the Lorentz force between the coil and the sheet metal is generally repulsive due to the Lenz's Law, which limits the practical application of this technology. To break this bottleneck, a dual-coil method is proposed to generate attractive Lorentz force, which is then used to form sheet metals. The theoretical principle of this method is presented, and an infinite element model is established to simulate the forming effect. The simulation results show that an A1060-O plate with a diameter of 140 mm and thickness of 1 mm can be attractively shaped under this method. The maximum axial displacement of the plate reaches 2.74 mm. Unfortunately, a dent exists in this situation. Further analysis indicates that this dent can be eliminated by increasing the inner and outer diameters of the coils. Further, it is found that when the capacitance value of the long pulse-width discharge circuit is set to 5.6 mF and the initial discharge voltage is set to 10.690 kV, the sheet metal attains the best shape.

A Dual-Coil Method for Electromagnetic Attraction Forming of Sheet Metals