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Article

Analysis of Proximity Consequences of Coil Windings in Electromagnetic Forming

by
Siddhant Prakash Goyal
1,*,
Mohammadjavad Lashkari
1,
Awab Elsayed
2,
Marlon Hahn
1 and
A. Erman Tekkaya
1
1
Institute of Forming Technology and Lightweight Components (IUL), TU Dortmund, Baroper Strasse 303, 44227 Dortmund, Germany
2
TU Dortmund, August-Schmidt-Straße 1, 44227 Dortmund, Germany
*
Author to whom correspondence should be addressed.
J. Manuf. Mater. Process. 2021, 5(2), 45; https://doi.org/10.3390/jmmp5020045
Submission received: 9 March 2021 / Revised: 30 April 2021 / Accepted: 4 May 2021 / Published: 8 May 2021
(This article belongs to the Special Issue Impulse-Based Manufacturing Technologies)
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Abstract

Multiturn coils are required for manufacturing sheet metal parts with varying depths and special geometrical features using electromagnetic forming (EMF). Due to close coil turns, the physical phenomena of the proximity effect and Lorentz forces between the parallel coil windings are observed. This work attempts to investigate the mechanical consequences of these phenomena using numerical and experimental methods. A numerical model was developed in LS-DYNA. It was validated using experimental post-mortem strain and laser-based velocity measurements after and during the experiments, respectively. It was observed that the proximity effect in the parallel conductors led to current density localization at the closest or furthest ends of the conductor cross-section and high local curvature of the formed sheet. Further analysis of the forces between two coil windings explained the departure from the “inverse-distance” rule observed in the literature. Finally, some measures to prevent or reduce undesired coil deformation are provided.
Keywords: electromagnetic forming; proximity effect; Lorentz forces; coil windings electromagnetic forming; proximity effect; Lorentz forces; coil windings

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MDPI and ACS Style

Goyal, S.P.; Lashkari, M.; Elsayed, A.; Hahn, M.; Tekkaya, A.E. Analysis of Proximity Consequences of Coil Windings in Electromagnetic Forming. J. Manuf. Mater. Process. 2021, 5, 45. https://doi.org/10.3390/jmmp5020045

AMA Style

Goyal SP, Lashkari M, Elsayed A, Hahn M, Tekkaya AE. Analysis of Proximity Consequences of Coil Windings in Electromagnetic Forming. Journal of Manufacturing and Materials Processing. 2021; 5(2):45. https://doi.org/10.3390/jmmp5020045

Chicago/Turabian Style

Goyal, Siddhant Prakash, Mohammadjavad Lashkari, Awab Elsayed, Marlon Hahn, and A. Erman Tekkaya. 2021. "Analysis of Proximity Consequences of Coil Windings in Electromagnetic Forming" Journal of Manufacturing and Materials Processing 5, no. 2: 45. https://doi.org/10.3390/jmmp5020045

APA Style

Goyal, S. P., Lashkari, M., Elsayed, A., Hahn, M., & Tekkaya, A. E. (2021). Analysis of Proximity Consequences of Coil Windings in Electromagnetic Forming. Journal of Manufacturing and Materials Processing, 5(2), 45. https://doi.org/10.3390/jmmp5020045

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