Modeling of the electromagnetic forming of sheet metals: state-of-the-art and future needs

Abstract The electromagnetic forming (EMF) process relies on a driving force that is induced by eddy current and magnetic field, both of which are generated in the workpiece by a transient current in a nearby coil. The high deformation rates achievable using this forming method enhances the formability of materials such as aluminum. Also, the dynamics of contact with the forming die can eliminate springback, an undesired effect that can be problematic in other forming techniques such as stamping. The advancement of the EMF technology is currently awaiting rigorous numerical modeling capabilities that can adequately simulate the forming process and be used to design the forming system. Such capabilities must be based on physical models that address the strong coupling between the electromagnetic, deformation and thermal response of the deforming workpiece and other system structure. In this paper, a brief exposition of the EMF method and its applications and a review of the existing models are given. In addition, a mathematical framework, which can be further developed numerically for the purpose of process simulation, is outlined. Finally, the paper discusses the challenges to advancing the EMF technology.