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A novel actuator for precise design of the spatial-distributed Lorentz force in electromagnetic sheet metal forming: process principle, optimization methodology, and experimental validation

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Abstract

This paper introduces a novel special-structure field shaper actuator designed to achieve precise spatial distribution of the Lorentz force in electromagnetic sheet metal forming. By precisely designing the bottom profile of the field shaper, the generated Lorentz forces on the workpiece can be controlled to meet various forming requirements. Moreover, the actuator incorporates multiple solenoid field coils to compensate for energy loss in the field shaper, effectively multiplying the input energy. The use of solenoid-type field coils allows for decoupling the optimization of system inductance from the design of the Lorentz force distribution, simplifying the reinforcement of the field coils and enhancing the limit input energy. The paper presents the analytical working principle and control rules to achieve the desired Lorentz force distribution and system inductance. Furthermore, a detailed design method based on numerical simulations is demonstrated to improve forming profiles and uniformity in thin-walled shell part forming. The simulation results indicate that the optimized actuator can reduce the radial thinning variance and the maximum thinning rate by 85% and 35%, respectively. The feasibility of the actuator and design method is verified through a series of comparison experiments, which exhibit a significant reduction in the maximum thinning rate (from 18 to 12%). This research represents a promising advancement in electromagnetic sheet metal forming, offering improved forming capabilities compared to conventional actuators.

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Funding

This work was supported by the National Natural Science Foundation of China (52107150, 52077092, and 51821005), the Fundamental Research Funds for the Central Universities (HUST: 2020kfyXJJS055), and the Key Research and Development Project of Hubei Province (2021BAA174).

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Authors and Affiliations

  1. Wuhan National High Magnetic Field Center, Huazhong University of Science and Technology, Wuhan, 430074, China

    Zixuan Zhang, Zhipeng Lai, Changxing Li, Wei Xu, Yang Hu, **aoxiang Li, Quanliang Cao, **aotao Han & Liang Li

  2. State Key Laboratory of Advanced Electromagnetic Engineering and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Zixuan Zhang, Zhipeng Lai, Changxing Li, Wei Xu, Yang Hu, **aoxiang Li, Quanliang Cao, **aotao Han & Liang Li

Authors
  1. Zixuan Zhang
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  2. Zhipeng Lai
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  3. Changxing Li
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  4. Wei Xu
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  5. Yang Hu
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  6. **aoxiang Li
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  7. Quanliang Cao
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  8. **aotao Han
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  9. Liang Li
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Contributions

All authors contributed to the study conception. Material preparation, data collection, and analysis were performed by Zixuan Zhang, Zhipeng Lai, and Changxing Li. The first draft of the manuscript was written by Zixuan Zhang and Zhipeng Lai. All authors commented on previous versions of the manuscript, and read and approved the final manuscript.

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Correspondence to Zhipeng Lai or Liang Li.

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Zhang, Z., Lai, Z., Li, C. et al. A novel actuator for precise design of the spatial-distributed Lorentz force in electromagnetic sheet metal forming: process principle, optimization methodology, and experimental validation. Int J Adv Manuf Technol 131, 4425–4445 (2024). https://doi.org/10.1007/s00170-024-13271-x

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