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Controlling the direction and profile of the electromagnetic force (EMF) is a key of improving the tube axial-uniformity and wall thickness during the electromagnetic forming process. In this regard, this article proposes a new tube electromagnetic-bulging topology using internal negative-external positive three-coil system. This structure is aimed at realizing effective bidirectional loading of axial and radial EMFs on the tube. An electromagnetic-structure coupling two-dimensional model is proposed to study the effect of the coil structure on the EF profile, bulging profile and the tube wall-thickness. The performance of the proposed method is compared with the traditional method through several performance metrics that include the electromagnetic force distribution cloud map, the tube bulging uniformity and its wall thickness. Numerical simulation results show that by changing the coil structure, the radial EMF profile can be effectively enhanced, and the free bulging contour of the tube can be further regulated. The additional axial EMF due to the proposed structure can promote the axial-flow of the material, thereby suppressing the reduction in the tube wall-thickness which is unavoidable using the traditional method. In comparison to the traditional single-coil system bulging, the maximum axial uniformity range of the tube is increased from 6.5mm to 35.2mm, and the wall thickness of the most severely thinned area is increased from 1.43mm to 1.77mm which verifies the effectiveness of the proposed method.

Tube Electromagnetic Free Bulging Based on Internal Negative-External Positive Three-Coil System