Simulation and Experimental Study on Inward Aluminum Tube Bead formation by Using Electromagnetic Forming with Taguchi Method

Electromagnetic forming is a high energy rate forming process which is applied for manufacturing and assembly of many parts that are used in automobile and aerospace industries. In this process, the electromagnetic body forces (Lorentz forces) are used to produce metallic parts. Joining high electrical conductivity parts by using electromagnetic forming process is as an innovative method. Therefore, it is very important to use a proper technique for assuring the quality of the Strength of Electromagnetically Joints. In this article, this process was simulated in ABAQUS. Then geometric, physical and mechanical specifications of the tube and coil are entered to subroutine and the magnetic pressure is obtained and by applying them on tube in ABAQUS software, agent analysis of the process and deformation of the work-piece is obtained. The effective process parameters such as discharge voltage, clearance between the tube and die, wall thickness and length of the tube on depth of bead were experimentally investigated by design of experiment technique based on Taguchi Method and signal to noise. Finally, found very good agreement between simulation and experimental results. The depth of bead in sequential coupled algorithm compared to experimental result had about 4% error.