Effects of Force Distribution and Rebound on Electromagnetically Formed Sheet Metal

Electromagnetic forming (EMF) is a high speed forming process that has been shown to increase the formability of aluminum alloys under certain conditions. Many authors have reported significant increases in formability; however, there is as of yet no complete understanding of the process. Obtaining a gain in formability is not the only factor that must be considered when studying EMF. The process rapidly generates significant forces which lead to the deformation of the material at very high rates. The applied forces depend on the shape of the electromagnetic coil used, which leads to force distributions that may not be ideal for forming a particular part. Once the sheet is accelerated it will travel at high speeds until it impacts the die. This high speed impact results in the sheet rebounding from the die. Both the force distribution and the rebound affect the final shape of the part. This paper presents the results of experimental and numerical study carried out to determine the effect of the force distribution and the rebound on samples of conical and "v-channel" geometry. It was found that both sample geometries are affected by the force distribution and the rebound, with the v-channel samples being considerably more affected. The results indicate that these effects must be carefully considered when EMF processes are designed