Electromagnetic reduction of a pre-formed radius on AA 5754 sheet

Electromagnetic (EM) forming is a high-speed forming process that uses the forces induced on a conductive workpiece by a transient high frequency current to form the workpiece into a desired shape. This paper presents the results of an experimental and numerical study carried out to determine whether EM forming techniques could be used to obtain sharper radii in aluminum alloy AA 5754 compared to that attained using conventional stamping process alone. AA 5754 1 mm sheet was formed into a v-shape with a 20 mm outer radius and then the radius was reduced or “sharpened” to 5 mm using EM forming. This “hybrid” process was modeled numerically to gain insight into the process and the challenges involved in the numerical simulation of the physical phenomena that are present in this process. As with any novel process, there are limitations and issues that must be addressed if this technique is to be implemented commercially; however; the research indicates that features that are not achievable using traditional stamping techniques can be obtained using EM forming.