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    Presentation Meraj Electromagnetic Joining

    Uploaded by

    Sagar Pawar
    This document provides an overview of electromagnetic joining. It discusses pulsed power processes like electromagnetic forming (EMF) and electrohydraulic forming (EHF) which use concentrated energy applied in small spaces and times. The document outlines the process physics, advantages like high productivity and applications in industries like medical, aerospace, automotive. It summarizes research on EMF/EMJ conducted at CSIR-AMPRI Bhopal, including design of coils and field shapers, joining of materials like Cu-SS and applications like Al waveguides. References on the topic are also provided.

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    Presentation Meraj Electromagnetic Joining

    Uploaded by

    Sagar Pawar
    42 views16 pages
    This document provides an overview of electromagnetic joining. It discusses pulsed power processes like electromagnetic forming (EMF) and electrohydraulic forming (EHF) which use concentrated energy applied in small spaces and times. The document outlines the process physics, advantages like high productivity and applications in industries like medical, aerospace, automotive. It summarizes research on EMF/EMJ conducted at CSIR-AMPRI Bhopal, including design of coils and field shapers, joining of materials like Cu-SS and applications like Al waveguides. References on the topic are also provided.

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    This document provides an overview of electromagnetic joining. It discusses pulsed power processes like electromagnetic forming (EMF) and electrohydraulic forming (EHF) which use concentrated energy applied in small spaces and times. The document outlines the process physics, advantages like high productivity and applications in industries like medical, aerospace, automotive. It summarizes research on EMF/EMJ conducted at CSIR-AMPRI Bhopal, including design of coils and field shapers, joining of materials like Cu-SS and applications like Al waveguides. References on the topic are also provided.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    42 views16 pages

    Presentation Meraj Electromagnetic Joining

    Uploaded by

    Sagar Pawar
    This document provides an overview of electromagnetic joining. It discusses pulsed power processes like electromagnetic forming (EMF) and electrohydraulic forming (EHF) which use concentrated energy applied in small spaces and times. The document outlines the process physics, advantages like high productivity and applications in industries like medical, aerospace, automotive. It summarizes research on EMF/EMJ conducted at CSIR-AMPRI Bhopal, including design of coils and field shapers, joining of materials like Cu-SS and applications like Al waveguides. References on the topic are also provided.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 16

    ELECTROMAGNETIC JOINING

    Meraj Ahmed

    Industry Meet
    At
    NAL Bengaluru
    18 Oct 2019

    CSIR-Advanced Materials and Processes Research Institute


    (AMPRI) Bhopal
    Overview

    Introduction
    Process/Physics
    Application
    EMF/EMJ@AMPRI
     Futuristic product development @ AMPRI
    Introduction: Pulsed Power

    Pulsed power: Concentration of energy in very small space


    and time and its sudden release

    Best analogy: Reverse process of a


    droplet of water falling on still liquid

    Pic from; http://wordsofjoy75.blogspot.in/2013/06/breaking-silence.html, Nov 2015


    High Velocity Forming
    High Velocity Forming/HERF: Forming process at high strain rate of 102/s
    (Velocity > 10 m/s) and above

    Explosive Electromagnetic Electrohydraulic


    Forming Forming (EMF) Forming (EHF)
    Process

    Pictures from BMAX (www.bmax.com)

    Electromagnetic Joining/ Electromagnetic Forming Electrohydraulic Forming


    Crimping
    Capacitor is discharged
    causing a time varying
    current to flow through
    a coil (EMF)/vaporizing wire (EHF).
    Current in the coil produces a
    transient magnetic field that
    induces eddy currents in the workpiece (EMF). Eddy currents generate an opposing magnetic field-
    causes the coil to repel the workpiece into the die.

     Current passed through an electrode pair placed in die cavity (filled with fluid) with or without
    bridgewire. Shockwave generated and same is applied to the workpiece (EHF)
    ADVANTAGES OF HERF PROCESSES
    • High Productivity, Simple tooling (one-sided die and no punch), same tools
    can be used for various thickness and materials
    • Non contact method, high surface finish and less tool wear
    • No lubrication, post cleaning rarely necessary
    • Automation friendly and reduces springback and prevents wrinkles, Uniform
    strain distribution
    • Pressure transmitted through a fluid medium- advantages of hydroforming are
    partially incorporated ( EHF)

    Challenges in using HERF Process


    • HERF processes are not suitable for large components and thick sheets
    • Working with High Voltage – safety concern
    • Higher capital investment for the equipment, Limited equipment suppliers
    • Deformation behaviour and formability at very high strain rates is not well
    understood in case of all the materials. Modelling of the processes is difficult.
    Application of EMF/EMJ in Industries
    • Medical (wheelchairs,
    walkers, canes etc.)
    • Research institute
    • Nuclear • Aerospace (flight contro

    • Home Appliances rods and torque tubes)


    • Power • Air conditioning (valve
    components)
    • Automobile ( dissimilar
    metal- torque tubes and
    shock absorbers etc.)
    Welding Crimping Forming Cutting Piercing

    Source: www.magneform.com; www.pulsar.co.il, www.iap.com, https://www.pstproducts.com)


    @AMPRI
    Electromagnetic joining & Forming:
    • Expertise on design of Coil and Field shaper (FS) for
    joining of symmetric and non-symmetric geometry
    • Electromagnetic Joining of Cu-SS, SS-Nb, SS-Ti, Al-Al,
    Al-SS, Al-MS, Al-Cu, Cu-Cu, Al-Al

    Rect. Profile
    Study on design of Coil

    • Effect of no. turns of coil, ID, OD, turn thickness on output


    (Inductance- current.. )
    • Effect of web width and material/slit geometry of FS on process
    parameters
    • Effect of coil configuration/design on force/deformation (using
    FEA)
    Effect of coil Design on the discharge current
    Table- Different dimension of coil
    Coil ID/OD (mm) N Turn Thickness Effect of t, ID, OD, N
    C1 91/220 4.40 8

    C2 91/220 4.33 8

    C3 55/200 2.4 3 t, D, N L

    C4 91/210 4.33 8

    C5 101/210 4.33 8

    256 kA
    Change in  225 kA
    Variation in Change in 
    frequency Δf 
    parameters current ΔI (kA)
    (kHz)
    Coil ID(91‐101) ‐9 ‐0.3
    Coil OD(210‐220) 32 1.7 Effect of no. of turn
    N (4.40‐ 4.33) ‐31 0.9
    Design of Coil and FS

    Rectangular FS Elliptical FS

    Flat forming coil


    Electromagnetic Joining
    Sample Design:
    Al-Al Joining joint design
    Al-MS electromagnetic
    joining
    Weld
    Zone
    Part 1
    D1 D2 Part 2 D3

    Failure criteria between part


    1 and weld
    (i) D12-D22 > 10D3 :– Zone 1
    (ii) D12 > D22 +10D2-30 :-
    Zone 2
    (iii) tf = [{√(D32 + 10D3)} -
    D3] / 2

    EDS 3 bank 1.5 SOD

    Set 1

    Set 2

    Set 3
    SS-Nb Joint SS-Ti Joint

    Helium Leak proof test


    Job description Leak Tightness
    (mbar-l/s)
    1. SS to Nb < 1E-10
    2. SS to Nb < 1.2E-10
    3. SS to Ti 1E-5
    4. SS to Ti 1E-5

    Cu-SS joining

    Leak proof test carried out at RRCAT


    DEVELOPMENT OF AL WAVEGUIDE AND SIMILAR PROFILE COMPONENTS
    • Reduction of weight
    • Better performance

    Source: ISRO exhb. BVM


    http://ec.europa.eu/research/transport/pdf/turin1010_0950_en.pdfwww.magnepress.com www.iap.com Courtesy: BARC, OSU, Pulsar
    REFERENCES
    References:
    Ahmed, M., Panthi, S.K., Ramakrishnan, N., Jha, A.K., Yegneswaran, A.H., Dasgupta, R. and Ahmed, S., 2011, “Alternative flat coil design for
    electromagnetic forming using FEM”, Transactions of Nonferrous Metals Society of China, 21(3), 618-625.
    Altynova, M., Hu, X., and Daehn, G.S., 1996, “Increased ductility in high velocity electromagnetic ring expansion”, Metallurgical and Materials
    Transactions A, 27A, 1837-1844.
    ASTM- E8/E8M Standard, “Standard test methods for tension testing of metallic materials [Metric]”, ASTM International.
    Ayres, R.A., Wenner, M.L., 1978, “Strain and strain-rate hardening effect on punch stretching of 5182-0 aluminium at elevated temperature”,
    Sheet Metal Industries, 55,1208-1216.
    Balanethiram, V.S. and Daehn, G.S., 1992, “Enhanced formability of interstitial free iron at high strain rate”, Scripta Metallurgica et Materialia ,
    27(12),1783-1788.
    Balanethiram, V.S., and Daehn, G.S., 1994a, “Hyperplasticity: Increased Forming Limits at High Workpiece Velocity”, Scripta Metallurgica et
    Materialia , 30, 515-520.
    Balanethiram, V.S., Hu, X., Altynova, M., 1994b, “Hyper plasticity: Enhance formability at High rates. J. Mater. Process. Technol., 1994, 45, p
    595-660.
    Banabic, D., 2010, “Sheet metal forming process”, Springer.
    Beerwald, C., Beerwald, M., Dirksen, U., et al., 2010, “Impulse hydroforming method for very thin sheets from metallic or hybrid Materials”, 4th
    International Conference on High Speed Forming, Columbus Ohio, USA, 150-158.
    Ben-Artzy, A., Stern, A., Frage, N., Shribman, V., Sadot, O., 2010, “Wave formation mechanism in magnetic pulse welding”, International Journal
    of Impact Engineering, 37, 397-404.
    Belyy, I.V., Fertik, S.M., and Khimenko, L.T., 1996, “Electromagnetic Metal Forming Handbook”, (A Translation of the Russian Book:
    Sprvochnik Po Magnitno-impul’ Snoy Obrabotke Metallov, Kharíkov State University, Kharíkov, Russia), Translated by M. M. Altynova,
    Material Science and Engineering Department, Ohio State University, Columbus.
    Bruno, E.J., 1968, “High-velocity forming of metals” American Society of Tool and Manufacturing Engineers Publication.
    Bonnen, J.J.F., Golovashchenko, S.F., Dawson, and Mamutov, A.V., 2013, “Electrode erosion observed in electrohydraulic dischages used in
    pulsed sheet metal forming”, Journal of Materials Engineering and Performance, 22 (12), 3946-3958.
    Caggiano, A., Christiana, J., D’Aguano, P., Hoppe, F. Inmam, N., Pfanner, G., 1961-1962, Republican Aviation Corporation intern and final
    progress report on “capacitor Discharge Metal Forming” Contact No. AF 33(600)42924, A.S.D. project 7-844.
    Casadei, A., and Broda, R., 2007, “Impact of vehicle weight reduction on fuel economy for various vehicle architectures”, (Arlington, VA: The
    Aluminum Association, Inc.), http://www.drivealuminum.org/research-resources/PDF /Research /2008/2008-Ricardo-Study.pdf, accessed on 2
    June 2016).
    Chace, W.G., Moore, H.K., 1959, “Exploding Wires”, Vol. 1. Plenum Press, New York, 9.
    Chu, Y-Y and Lee, R S, 2010, “Effects of blank design on the electromagnetic flanging process”, Proceedings of the Institution of Mechanical
    Engineers, Part B: Journal of Engineering Manufacture, 224, 75-86.

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