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Optimization of electromagnetic forming process parameters for curved specimens based on CCD-RSM
Jie Tang1, Mingcai Li2, Tao Wang1
1Department of Aeronautical Engineering, School of Aeronautical Engineering, Civil Aviation University of China, No 2898, Jin Bei Road, Tianjin, 300300, China.
Scientific Reports
|September 25, 2025
Summary
This study optimizes electromagnetic forming for curved workpieces, like rocket tanks, using an elliptical coil. Optimal parameters achieve a precise 100 mm forming diameter, enhancing manufacturing efficiency.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Applied Electromagnetics
Background:
- Electromagnetic forming (EMF) is a high-speed, non-contact manufacturing process.
- Applications span aerospace and automotive industries.
- Novel elliptical coil design for curved workpieces, mimicking rocket propellant tanks, is introduced.
Purpose of the Study:
- Optimize key parameters for EMF of curved workpieces.
- Investigate the influence of discharge voltage, coil inner diameter, and coil width.
- Achieve a target forming diameter of 100 mm.
Main Methods:
- Finite element simulations using COMSOL.
- Validation with experimental data for AA 2219-O aluminum alloy.
- Central composite design (CCD) for sensitivity analysis.
- Response surface methodology for optimization.
Main Results:
- Discharge voltage, coil inner diameter, and coil width significantly impact forming results.
- Optimal parameters identified: 4403.27 V discharge voltage, 67.7 mm coil inner diameter, 3.39 mm coil width.
- Achieved forming diameter closely matched the 100 mm target.
Conclusions:
- The developed model accurately predicts EMF outcomes for curved parts.
- Optimization methodology successfully identifies parameters for precise forming.
- This research advances EMF applications for complex geometries in high-tech industries.
