An Efficient Computational Model for Magnetic Pulse Forming of Thin Structures

Area of Science:

• Materials Science
• Computational Mechanics
• Manufacturing Engineering

Background:

• Electromagnetic forming (EMF) is a high-speed sheet metal forming process.
• 3D modeling of EMF presents computational challenges due to strongly coupled multi-physics.
• Existing numerical methods offer trade-offs between accuracy and computational time.

Purpose of the Study:

• To develop a novel approach for reducing computational time in 3D electromagnetic forming simulations.
• To maintain reasonable accuracy while decreasing CPU time for magnetic pulse forming (MPF) analysis.
• To enhance existing 3D finite element analysis (FEA) toolboxes for improved efficiency.

Main Methods:

• Utilized a 3D finite element analysis toolbox developed at CEMEF.
• Simulated magnetic pulse forming (MPF) of thin sheets under various conditions.
• Implemented innovative techniques including a termination criterion and adaptive re-meshing.
• Tested and verified the applicability of a newly implemented solid shell element for thin structures.

Main Results:

• The novel approach successfully reduced simulation CPU time for 3D EMF.
• The implemented solid shell element provided results comparable to standard tetrahedral MINI elements.
• Simulation time was significantly reduced with the solid shell element compared to traditional methods.
• Adaptive re-meshing and termination criteria effectively addressed simulation challenges.

Conclusions:

• The developed approach offers a viable solution for efficient and accurate 3D electromagnetic forming simulations.
• Solid shell elements show promise for modeling thin structures in EMF, balancing accuracy and computational cost.
• The study contributes to overcoming the computational burden associated with high-speed forming process modeling.