Comparison of two different simulation algorithms for the electromagnetic tube compression

Abstract

Simulation tools especially for the electromagnetic forming process (EMF process) offer the opportunity to analyse the formation process and its effects already in the development stage. The EMF process is a high-dynamic process with high transformation velocities. The deformation results from the interaction of the electrical current in the forming coil and the induced eddy current in the workpiece, represented by the Lorentz force. Most of the simulation tools and models for the EMF process are limited to small deformations. The connection between electromagnetic field and spatiotemporal evolution of the deformation of the workpiece is not negligible for example for working out a door handle recess in the automotive industry. This paper presents a comparison of a custom loose-coupled simulation model and a more accurate sequential-coupled approach. The deviations between the two simulation models increase with time, so that the loose-coupled approach leads to an overestimation of the final deformation. The correspondence of the sequential-coupled simulation with the measurement result is much better than for the loose-coupled simulation.