Electromagnetic Forming Paper v1 PDF

ANSYS Conference & 32
nd
CADFEM Users' Meeting 2014
June 4 6, 2014, NCC Ost, Messe Nrnberg
User-friendly FEA for Electromagnetic Forming
Dr. Charlotte Beerwald, Moritz Beerwald,
Dr. Uwe Dirksen, Artur Henselek
Poynting GmbH,
Dortmund, Germany
nd
Simulation of Electromagnetic Forming
with SMU-SimTool
User-friendly FEA of EMF with SMU-SimTool Electromagnetic
forming
process EMF
nd
Company Profile
POYNTING company performs contract research, development and
equipment manufacturing in the field of
Pulsed Power Technologies
Our intention is to bring new research-based technologies into application and
make them available for diverse industrial branches.
Fields of activity comprise
components and assemblies for pulsed power systems
(high current, high voltage supplies)
as well as complete turn-key systems,
to design and build unique instrumentation
for research and scientific use, and
customer-specific equipment for industrial series
production when processes are based on high-level
electrical or electromagnetic field impulses
Pulse Modulator for ESS, Lund
with integrated
High Voltage Power Supply
225 kW, 6 kV
nd
Characteristic for this technology is that a large amount of energy [up to Megajoule range] will be charged
and stored in a capacitance or in an inductance or in an accelerated mass to be suddenly discharged within
a very short impulse of a few micro- or milliseconds.
As a result of this it is possible to generate temporarily extremely high power levels [in a Gigawatt range],
which demands high electrical, but most of all mechanical requirements to the used components and
structures.
Typically the peak values are much higher than the mean values. This can be used to initiate threshold
reactions or to benefit from special non-linear effects.
Pulsed power technologies can be used advantageously if it is possible to achieve a better result compared
to conventional methods, or if the pulsed power principle even enables a desired application for the first
time.
Pulsed Power Technologies
What does Pulsed Power mean?
nd
HV Power Supplies
power categories
up to several
hundred kW
Pulse Generators
e.g. SMU machines
compact or
modular design
Components, Individual Parts,
Assemblies
Tool Coil Design
Feasibility Studies
Product Range - Hardware
Pulsed Power
Equipment
The hardware product range of Poynting mainly
consist of high-voltage power supplies, pulse
generators, and accessory equipment
Normally, in our high-current and high-voltage
applications the high forces induced by the
magnetic fields are undesired
Nevertheless, applications exists where these high
forces are welcome.
In the Electromagnetic Forming EMF process the
magnetic pressure impulse is used to form and
join metallic workpieces
SMU machines are special pulse generators used
for the EMF process
On the left side two coils for the EMF process are
shown
nd
High Current
Switch
Workpiece
(tubular)
C
L
i
R
i
EMF Process Principle
p = 1/2
0
H
2
0
: permeability of
vacuum
Magn.
Pressure
Process Time
H: magn. field
strength
On the left side you can see a simplified process setup for
Electromagnetic Forming
The pulse generator is represented by its equivalent electrical circuit
with resistance R
i
, inductance L
i
, and capacitor bank C
The Electromagnetic Forming process starts with charging the
capacitor bank
The energy in the capacitor bank is discharged if the high current switch
is closed
The high current switch must switch very fast and the power loss must
be low (max. current can be up to 1000 kA)
If the high current switch is closed a current starts to flow through the
coil
Electromagnetic Forming is a High Velocity Forming Process using the energy density
of a pulsed magnetic field to form or accelerate
workpieces of good electrical conductivity.
Pulse generator
Coil
Current
Process Time
Compression Coil
nd
Magnetic Field Strength H
(pressure zone)
EMF Process Principle
p = 1/2
0
H
2
0
: permeability of
vacuum
Magn.
Pressure
Process Time
H: magn. field
strength
Coil
Current
Process Time
As the current flows through the coil a magnetic field
develops around the coil
The magnetic field induces eddy currents in the metallic
workpiece which also develop a magnetic field
The higher the electrical conductivity of the workpiece the
higher the eddy currents and the developed magnetic field
High Current
Switch
Workpiece
(tubular)
C
L
i
R
i
Compression Coil
nd
Coil
Current
Process Time
High Current
Switch
Workpiece
(tubular)
C
L
i
R
i
Magnetic Field Strength H
(pressure zone)
I (t) H (t) p (t)
SMU Process Principle
p = 1/2
0
H
2
0
: permeability of
vacuum
Magn.
Pressure
Process Time
H: magn. field
strength
If the magnetic field strength H is known the magnetic
pressure p can be determined
If the pressure p is high enough the workpiece is plasticly
formed
The current I directly influences the pressure and accordingly
the forming of the workpiece
Electromagnetic Forming is a high velocity process and the
process duration of workpiece forming is in the range of 10
s to 1 ms
Compression Coil
nd
Compression
Expansion
Flat
Forming
Electromagnetic Forming is a High Velocity Forming Process using the energy density of a
pulsed magnetic field to form or accelerate workpieces of good electrical conductivity.
Process Types
resulting of the coil-workpiece arrangement
Capacitor
Bank
High Current
Switch
Workpiece
(tubular)
Compression Coil
C
L
i
R
i
SMU Process Principle
Electromagnetic Forming can be used to form tubes and
sheets
The used process type depends on the coil shape and
the coil-workpiece arrangement
1. Flat forming:
A flat spiral coil can be used to form sheet metals
2. Compression:
A metallic tube inside of a spiral coil can reduce
the radius of the tube
3. Expansion:
A metallic tube outside of a spiral coil can expand
the radius of the tube
nd
Fluid Pipes for Automotive Applications
(coated aluminium tube and steel fitting)
Assembling and Oil Tight Sealing of
Hydraulic Compen-
sating Bellows
Joining of Multi-Material Components
(high strength FRP aluminium parts)
Chassis
Components
(Cross-Steering
BMW M3 CSL)
Joining by EMF Tubes + Profiles
Joining of Car Body Components
(aluminium spaceframe components)
Electromagnetic Forming can be used for
joining, cutting, and forming of tubes and
sheet metals
Joining of tube-shape workpieces is the most
important process type at the moment. It is a
mechanical joining where at least one joining
partner is formed. The join can be realized
as force-fit and form fit. At high impact
velocities a firmly bonded join is also
possible
Due to the contact-less forming process
no tool marks on the workpiece
coated workpieces can be used
Only the formed workpiece must have a
good electrical conductivity
Joins with material combinations of
different metals and metal / non-metal
can be manufactured
nd
Fluid Pipes for Automotive Applications
(coated aluminium tube and steel fitting)
Assembling and Oil Tight Sealing of
Hydraulic Compen-
sating Bellows
Joining of Multi-Material Components
(high strength FRP aluminium parts)
Chassis
Components
(Cross-Steering
BMW M3 CSL)
Joining by EMF Tubes + Profiles
Joining of Car Body Components
(aluminium spaceframe components)
nd
Research Project
Grant Agreement Nr: 609039
Collaborative Project - FP7-2013-NMP-ICT-FOF(RTD)
Optimization of joining processes for new
automotive metal-composite hybrid parts
nd
Relevant Properties
for Simulation of EMF Process
SMU-COMPACT 3020-FS (max. 30 kJ, max. 20 kV)
Simulation of a manufacturing process requires
an understanding of the relevant process
components and properties
For the EMF process an important process
parameter is the current. It mainly depends on
the SMU machine, the energy conduction system
and the consumer load which consist of the tool
coil and the workpiece
These components build the discharge circuit
which can be simplified to the equivalent
electrical circuit below. The consumer load is
described with R
a
and L
a
separatly because
these values changes during the process
nd
Relevant Properties
for Simulation of EMF Process
SMU-COMPACT 3020-FS (max. 30 kJ, max. 20 kV)
The current is responsible for creation of the magnetic fields
The magnetic fields creates the magnetic pressure which deforms the
workpiece
Deformation of the workpiece changes the inductance of the
consumer load
Joule heating in the conductors increase the temperature in the
conductors
Changes in the temperature also changes electrical and mechanical
properties of the components (workpiece, coil, etc.)
nd
Physical Domains and their Dependencies
Electrical
oscillating
circuit
Electro-
magnetic
field
Temperature
Structural
mechanics
Modeling of the Electromagnetic Forming requires considering the
physical domains:
Electrical circuit
Electromagnetic field
Structural mechanics
Temperature
nd
Physical Domains and their Dependencies
Electrical
oscillating
circuit
Electro-
magnetic
field
Temperature
Structural
mechanics
The physical domains depend from each other and their values
change over process time
Simulation of the EMF process requires one simulation which can
solve all physical domains or coupling of different simulations which
individually solve the physical domains
nd
Element Selection
Electrical
oscillating
circuit
Electro-
magnetic
field
Temperature
Structural
mechanics
Phys. Domain
Circu124 / Circu125
2D 3D
Circu124 / Circu125
Plane233: 2D 8 node electromagnetic solid
Plane223: 2D 8 node coupled-field solid
Plane223: 2D 8 node coupled-field solid
Solid226: 3D 20 node coupled-field solid
Solid226: 3D 20 node coupled-field solid
Solid236: 3D 20 node electromagnetic solid
Electrical circuit
Electromagn. field
Structural mech.
Temperature
Required components of the electrical circuit can be
described using the elements Circu124 and Circu125
The electromagnetic fields can be presented using the
element Plane223 for 2D and Solid236 for 3D
The structural mechanics and the changes in
temperature can be described using the coupled-field
elements Plane223 for 2D and Solid226 for 3D
nd
Simulation System Model
nd
Simulation System Model
The simulation model:
Implementation starts with ANSYS v13 using ANSYS classic
Fully automized using APDL scripts
Two main sub-simulations (sparse solver)
El-Mag-Simulation solves electrical circuit and electromagnetic fields
Mech-Ther-Simulation solves structural mechanics and changes in temperature
Both sub-simulations uses the same mesh. Mesh is automatically generated using a feature-
based description of the process components
The types of the elements are updated between the sub-simulation and results are transfered
using the LDREAD APDL-command
After each sub-simulation results are post-processed and can be evaluated by the user
Number of sub-steps in the Mech-Ther sub-simulation are adjusted according to the maximum
velocity of elements
nd
Meshing
r
z
Compression Coil
Field shaper
Tube
Mandrel
Symmetry axis
at r = 0
Skin depth
s
in conductors
(coil, field shaper, workpiece)
must be considered
Air must be meshed
=
1

: Frequency of current
: Magnetic permeability
: Electrical conductivity
Skin depth
Skin depth
s
in copper
at = 10 kHz:
s
= 660 m

nd
Meshing
r
z
Compression Coil
Field shaper
Tube
Mandrel
Symmetry axis
at r = 0
Skin depth
s
in conductors
(coil, field shaper, workpiece)
must be considered
Air must be meshed
=
1

: Frequency of current
: Magnetic permeability
: Electrical conductivity
Skin depth
Skin depth
s
in copper
at = 10 kHz:
s
= 660 m
Determination of the electromagnetic fields requires meshing the air between

the workpiece, joining partner, coil, and field shaper
1
The EMF process uses AC currents which requires considering the skin effect
in meshing the components. The skin effect describes the effect that the
current density is not equal across the cross section at AC currents. Instead of
it decreases from the surface to the inner parts. At the skin depth the current
is decreased to 1/e of the current on the surface.
Describing the skin effect accurately requires suitable number of elements
and elements sizes in the coil, field shaper, and workpiece
1
Field shaper is used to concentrate the magnetic field generated by the coil
nd
Coupling of Electrical Circuit and Coil
r
z
Symmetry axis
at r = 0
Compression Coil
Field shaper
Tube
Mandrel
nd
Coupling of Electrical Circuit and Coil
r
z
Symmetry axis
at r = 0
Compression Coil
Field shaper
Tube
Mandrel
The pulse generator and the energy conduction system are summarized in the
equivalent electrical circuit using the resistor R, the inductor L and the
capacitor C
The electrical circuit is coupled to the coil elements using a constraint
equation
At the beginning of the simulation the capacitor is initialized with the load
voltage U
circuit
nd
Contact Definition
Using one mesh for El-Mag sub-simulation and Mech-Ther sub-
simulations means that between the contact partners always
exist elements representing the air. These elements are required
for computation of the magnetic field
A contact gap of at least 50 m must be defined to avoid
collapsing of the air elements
nd
System Model of SMU-SimTool
nd
System Model of SMU-SimTool
The simulation model for the EMF process is rather complicated
The product and process designer do not want to take care on these aspects!
Poynting has developed the simulation tool SMU-SimTool which hides the setup of a 2D
process simulation and the required pre- and post-processing for the EMF process
SMU-SimTool is implemented for operating systems Windows and Linux
SMU-SimTool is separated in two components: frontend and backend
SMU-SimTool frontend
Installed on user side
Feature-based modelling of the product and process components. Process
components can be selected from libraries.
Configuration of main parameters of simulation process such as final process
time, contact gap and so on
Controlling of simulation (start, stop, restart)
Visualization of already post-processed relevant simulation results
SMU-SimTool backend
Running at Poynting
SMU-SimTool frontend transfers product and process data to the backend if the
users starts or restarts the simulation
The backend automatically starts the simulation model on ANSYS
After each simulation step relevant results are post-processed and transferred to
the users SMU-SimTool frontend for evaluation
nd
SMU-SimTool: Modelling in 5 Steps
nd
SMU-SimTool: Modelling in 5 Steps
Modelling of the product and process components is feature-based
For each component a base type is selected and further detailed using a small
number of parameters
Material, coil, and pulse generators can be easily selected from libraries
The selected SMU machine is configured by switching on the requested
capacitor banks and defining the requested load energy or load voltage
Only five steps are required for defining the model!
nd
SMU-SimTool: Application Example
r
z
Compression Coil Field shaper
Tube
75mm x 2.5mm
Mandrel with
conical groove
Symmetry axis
at r = 0
Desired time curves
at certain position z = 0
nd
r
z
Compression Coil
Field shaper
FF75l15
Tube, AW6060 T6
75mm x 2.5mm
Mandrel, S235
conical groove
Symmetry axis
at r = 0
Desired time curves
at certain position z = 0
The application examples shows the simulation of the EMF process type
compression. A tube is formed on an inner joining partner. Therefore a coil with
four turns and a field shaper are used.
After each load step the following data is sent to the SMU-SimTool frontend
and displayed as curve
Current
At one specified location on the outer side of the tube
Displacement in x-direction
Velocity in x-direction
Magnetic pressure
On next page:
Beside time data also contour plots are created and transferred to the SMU-
SimTool frontend
All data transferred to the SMU-SimTool frontend is stored locally and can offline
be further evaluated
nd
nd
Summary and Outlook
Fully-coupled simulation for EMF process
APDL scripts with two main simulations using 1 mesh
User-friendly FEA of EMF process with SMU-SimTool
No FEA simulation knowledge required
Fast modelling due to feature-based modelling
Define process time and press START button
Relevant simulation results are already post-processed
Time data
Contour plots
Future work
Multi-frame restart
Automatic air-remeshing in 3D

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ANSYS Conference & 32

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Determination of the electromagnetic fields requires meshing the air between

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