Electromagnetic Forming and Perforation of Tubes: Modeling, Simulation, and Validation

Abstract

Electromagnetic forming and perforation (EMFP) is an innovative practice where magnetic forces are used for simultaneous forming and perforation operation. This method is complex, which involves a high strain rate as well as high transformation velocities. It is carried out in a short duration of time, and it includes multiple operations, which increases the complexity in understanding the shearing and forming behavior of the material. To understand this behavior, coupled and non-coupled simulation models have been developed and compared with experimental results. Material and failure models are used for simulating the material behavior at a high strain rate. At lower discharge energy, the coupled model failed to capture the initiation of perforation, but numerical results are found 96% in agreement with experimental results. While on the other hand, on the same discharge energy, non-coupled simulation shows 94% agreement and it succeeded in capturing the initiation of perforation. The von-Mises stresses found in all cases are more than 4e+08 Pa which is found higher than the ultimate strength of the material which is resulting in shearing. The failure patterns obtained in finite element analysis (FEA) simulation for both pointed and concave punch perforation show good agreement with general finding in experiments which shows the prediction capability of developed models.