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. Electromagnetic forming is a high-speed sheet metalforming technique to form metallic sheets by applying magnetic forces. In comparison to the conventional sheet metal forming process, electromagneticforming is a process with an extremely high velocity and strain rate, which can be effectively used for the forming of certain difficult-to-form metals.During electromagnetic forming, it is important to recognise the effects ofprocess parameters on the deformation and sheet thickness variation of thesheet metal. This research focuses on the development of a numerical modelfor aluminium alloy (AA6061-T6) to analyse the effects of three processparameters, namely voltage, sheet thickness and number turns of the coils, on the deformation and thickness variation of the sheet. A two-dimensional fully coupled finite-element (FE) model consisting of an electrical circuit, magnetic field and solid mechanics was developed and used to determine the effect ofchanging magnetic flux and system inductance on sheet deformation.Experiment validation of the results was performed on a 28 KJ electromagnetic forming system. The Taguchi orthogonal array approach was usedfor the design of experiments using the three input parameters (voltage,sheet thickness and number of turns of the coil). The maximum error betweennumerical and experimental values for sheet thickness variation was observedto be 4.9 %. Analysis of variance (ANOVA) was performed on the experimental results. Applied voltage and sheet thickness were thesignificant parameters, while the number of turns of the coil had an insignificant effect on sheet deformation. The contribution ratio of voltageand sheet thickness was 46.21 % and 45.12 % respectively. The sheetdeformation from simulations was found to be in good agreement with theexperimental results.

mechanical sciences

Numerical and experimental investigation of the effect of process parameters on sheet deformation during the electromagnetic forming of AA6061-T6 alloy