3D modeling and deformation analysis for electromagnetic sheet forming process

Electromagnetic forming (EMF) is a high-speed forming method which can be quite effective in increasing the forming limits of metal sheet. However, the EMF process is complicated due to magnetic-structure coupling analysis. Numerical simulation offers an opportunity to overcome the problem. Nevertheless, most present models for EMF process are limited to 2D axisymmetric model. So, a three-dimensional (3D) finite element model was established to analyze the electromagnetic sheet bulging. The contact between the sheet and the die and the effect of sheet deformation on the magnetic field analysis were both taken into consideration during the forming process. The simulation results of deflection at the sheet center and 20 mm away from the center were in agreement with the experimental ones. The plastic strain energy and plastic strain were analyzed.