Analytical and Numerical Analysis of Geometrical and Physical Significant Parameters on the Strength of Electromagnetically Joints

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. In this research work, the effect of important parameters of process such as discharge voltage, radius and width of rectangular groove on the strength of assembled products were studied by using finite element method and design of experiment. After introducing the governing equations, the output of these equations were applied in simulation as a pressure on work-piece. In this simulation, an axisymmetric model was used in analysis and Johnson-Cook theory was applied due to high strain rate to show the plastic behavior of materials. Finally, the numerical results were compared with the results reported by other researchers. As a result, the contact surface at bottom of the groove increases with the increase of the voltage energy and more filling groove, increasing strength of joint. Also Strength of joint increases, due to create partial shearing of the tube at the groove edge and interference stresses at the tube and mandrel interface.