Analysis, simulation and experimental study of electromagnetic forming of titanium bipolar plate with arc-shaped uniform pressure coil

IF 2.6 3区材料科学 Q2 ENGINEERING, MANUFACTURING

International Journal of Material Forming Pub Date : 2024-03-20 DOI:10.1007/s12289-024-01818-y

Qiangkun Wang, Junrui Xu, Shaobo Wang, Yudong Zhao, Yuanfeng Wang

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Abstract

In the electromagnetic forming (EMF) titanium bipolar plates (BPPs), a reasonable coil structure can provide higher forming efficiency and repeatability. An arc-shaped uniform pressure coil (UPC) is proposed, and an efficient and reliable multiphysics sequentially coupled analytical model is established. Through the LS-DYNA numerical model and the fitted current curve obtained from experiments, the predictive capabilities of equivalent circuit parameters and dynamic phenomena are verified, and the rationality of the magnetic shielding assumption and magnetic flux uniform distribution are evaluated. Starting from the durability and forming efficiency of the coil, the optimal coil geometry in analytical form is constructed. The study found that there is an optimal solution for the height of the primary coil, wire thickness, primary and secondary side gap, which are 18.3 mm, 2.7 mm, and 3.2 mm, respectively. Based on this, under the discharge capacitor of 100 μF, acceleration distance of 2 mm, and driven by 0.3 mm thick Cu110, a TA1 titanium BPP with a channel depth-to-width ratio of 0.53 was successfully manufactured. Its maximum thinning rate is 18.2%, the maximum fluctuation rate does not exceed 2.5%, and the filling rate of the channel above 95%. Overall, this study provides theoretical basis and reference for the design of UPC in EMF for BPPs.

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带弧形均压线圈的钛双极板电磁成形的分析、模拟和实验研究

在电磁成形（EMF）钛双极板（BPP）中，合理的线圈结构可以提供更高的成形效率和重复性。本文提出了一种弧形均压线圈（UPC），并建立了高效可靠的多物理场顺序耦合分析模型。通过 LS-DYNA 数值模型和实验得到的拟合电流曲线，验证了等效电路参数和动态现象的预测能力，评估了磁屏蔽假设和磁通均匀分布的合理性。从线圈的耐用性和成形效率出发，构建了最佳线圈几何形状的解析形式。研究发现，一次线圈高度、导线厚度、一次侧间隙和二次侧间隙分别为 18.3 毫米、2.7 毫米和 3.2 毫米，均有一个最优解。在此基础上，在放电电容为 100 μF、加速距离为 2 mm 的条件下，由 0.3 mm 厚的 Cu110 驱动，成功制造出通道深宽比为 0.53 的 TA1 钛 BPP。其最大减薄率为 18.2%，最大波动率不超过 2.5%，通道填充率高于 95%。总之，本研究为 BPP 的电磁场中 UPC 的设计提供了理论依据和参考。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Material Forming ENGINEERING, MANUFACTURING-MATERIALS SCIENCE, MULTIDISCIPLINARY

CiteScore

5.10

自引率

4.20%

发文量

审稿时长

>12 weeks

期刊介绍： The Journal publishes and disseminates original research in the field of material forming. The research should constitute major achievements in the understanding, modeling or simulation of material forming processes. In this respect ‘forming’ implies a deliberate deformation of material. The journal establishes a platform of communication between engineers and scientists, covering all forming processes, including sheet forming, bulk forming, powder forming, forming in near-melt conditions (injection moulding, thixoforming, film blowing etc.), micro-forming, hydro-forming, thermo-forming, incremental forming etc. Other manufacturing technologies like machining and cutting can be included if the focus of the work is on plastic deformations. All materials (metals, ceramics, polymers, composites, glass, wood, fibre reinforced materials, materials in food processing, biomaterials, nano-materials, shape memory alloys etc.) and approaches (micro-macro modelling, thermo-mechanical modelling, numerical simulation including new and advanced numerical strategies, experimental analysis, inverse analysis, model identification, optimization, design and control of forming tools and machines, wear and friction, mechanical behavior and formability of materials etc.) are concerned.