Electromagnetic Flanging Process of Runway-shaped Holes in 2024 Aluminum Alloy

CHEN Lixue; MAO Wenjie; SUN Yiran; SU Hongliang; MEN Xiangnan; DENG Tao; ZHANG Song; ZHOU Xiong; LI Junhui; HUANG Liang

doi:10.3969/j.issn.1674-6457.2025.09.002

PDF(13131 KB)

Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (9) : 14-26. DOI: 10.3969/j.issn.1674-6457.2025.09.002

Light Alloy Forming

Electromagnetic Flanging Process of Runway-shaped Holes in 2024 Aluminum Alloy

CHEN Lixue¹, MAO Wenjie², SUN Yiran², SU Hongliang^1,*, MEN Xiangnan¹, DENG Tao¹, ZHANG Song¹, ZHOU Xiong¹, LI Junhui², HUANG Liang²

Author information +

History +

Abstract

The work aims to investigate the electromagnetic flanging process of 2024-O aluminum alloy obround holes, focusing on the effects of coil series layers, discharge voltage, and discharge capacitance on mold-fitting performance and thinning rate. Through finite element numerical simulation and analysis of the electromagnetic flanging process, the effect of various process parameters on flanging results was systematically examined. The forming quality was evaluated using two indicators: mold-fitting gap and thinning rate, with the optimal forming criteria defined as achieving minimal mold-fitting gap while maintaining thinning rate below 20%. The results demonstrated that when employing more than two series-connected coil layers, the third layer exhibited significantly reduced effect on sheet metal deformation due to excessive distance from the workpiece. Excessive discharge voltage induced overspeed deformation leading to mold collision and poor forming quality, while insufficient voltage failed to provide adequate deformation velocity. Lower capacitance values corresponded to higher discharge frequencies, resulting in greater initial deformation velocities. The critical parameters affecting forming quality include the number of series-connected coil layers, discharge voltage, and discharge capacitance. For obround hole flanging, the optimal configuration combines two series-connected coil layers with 11 kV discharge voltage and 106.5 μF capacitance. This parameter combination achieves mold-fitting gaps meeting process requirements, with a mere 0.02 mm discrepancy between simulated and measured values for the apex spacing between circular edges.

Key words

2024 aluminum alloy / electromagnetic flanging / forming accuracy / finite element / process optimization

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

CHEN Lixue, MAO Wenjie, SUN Yiran, SU Hongliang, MEN Xiangnan, DENG Tao, ZHANG Song, ZHOU Xiong, LI Junhui, HUANG Liang. Electromagnetic Flanging Process of Runway-shaped Holes in 2024 Aluminum Alloy[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 14-26 https://doi.org/10.3969/j.issn.1674-6457.2025.09.002

References

[1] MAJUMDAR S, SINHA A, DAS A, et al.An Insight View of Evolution of Advanced Aluminum Alloy for Aerospace and Automotive Industry: Current Status and Future Prospects[J]. Journal of the Institution of Engineers (India): Series D, 2024(1): 1-18.
[2] YU Z X, XIAO A, YAN Z Q, et al.Enhance Forming Properties of 7075-T6 Aluminium Alloy by Two-Step Electromagnetic Forming and Electrical Pulse Treatment[J]. The International Journal of Advanced Manufacturing Technology, 2024, 135(7): 3285-3300.
[3] 时恬, 黄亮, 谢冰鑫, 等. 铝合金双曲率薄壁件电磁渐进辅助拉伸成形工艺方案设计与开发[J]. 精密成形工程, 2024, 16(3): 52-61.
SHI T, HUANG L, XIE B X, et al.Design and Development of Electromagnetic Progressive Assisted Stretching Forming Process for Aluminum Alloy Double Curvature Thin-Walled Parts[J]. Journal of Netshape Forming Engineering, 2024, 16(3): 52-61.
[4] AFRASIAB M, HOJJAT Y, FARAJI G, et al.Formability Enhancement of Ultrafine-Grained Pure Copper Sheets Produced by Accumulative Roll Bonding Aided by Electromagnetic Forming[J]. The International Journal of Advanced Manufacturing Technology, 2022, 120(11): 7445-7459.
[5] ZHANG X, HUANG Y K, WANG Y Y, et al.Numerical Simulation and Experimental Study on Electromagnetic Punching-Flanging Process of 6061 Aluminum Alloy Sheets[J]. Journal of Manufacturing Processes, 2022, 84: 902-912.
[6] 邱立, 罗宝妮, 何琴, 等. 基于凸型线圈双向电磁力加载的管件电磁翻边成形[J]. 热加工工艺, 2024, 53(9): 152-158.
QIU L, LUO B N, HE Q, et al.Electromagnetic Flanging Forming of Pipe Fitting Based on Bidirectional Electromagnetic Force Loading of Convex Coil[J]. Hot Working Technology, 2024, 53(9): 152-158.
[7] DEWANG Y, SHARMA V.Sheet Metal Shrink Flanging Process: A Critical Review of Current Scenario and Future Prospects[J]. Materials and Manufacturing Processes, 2023, 38(6): 629-658.
[8] 刘昊, 黄亮, 孙怡然, 等. 2024铝合金锥形孔电磁翻边线圈设计及成形工艺研究[J]. 中国机械工程, 2024, 35(12): 2149-2156.
LIU H, HUANG L, SUN Y R, et al.Research on Coil Design and Forming Processes of 2024 Aluminum Alloy Conical Hole Electromagnetic Flanging[J]. China Mechanical Engineering, 2024, 35(12): 2149-2156.
[9] DEWANG Y, PUROHIT R, TENGURIA N.A Study on Sheet Metal Hole-Flanging Process[J]. Materials Today: Proceedings, 2017, 4(4): 5421-5428.
[10] PSYK V, RISCH D, KINSEY B L, et al.Electromagnetic Forming—A Review[J]. Journal of Materials Processing Technology, 2011, 211(5): 787-829.
[11] YU H P, JIN Y Y, CHENG X.Formability of 2195-T4 Al-Li Alloy Sheet by Electromagnetic Forming[J]. Journal of Materials Research and Technology, 2024, 30: 9325-9336.
[12] 韩飞, 莫健华, 黄树槐. 电磁成形技术理论与应用的研究进展[J]. 锻压技术, 2006, 31(6): 4-8.
HAN F, MO J H, HUANG S H.Theoretical Study and Application of Electromagnetic Forming Technology[J]. Forging & Stamping Technology, 2006, 31(6): 4-8.
[13] DESTEFANI J D.Tough Materials Revive Interest in High-velocity Forming[J]. Manufacturing Engineering, 1997, 11: 70-74.
[14] BESONG L I, BUHL J, BAMBACH M.Increasing Formability in Hole-Flanging through the Use of Punch Rotation Based on Temperature and Strain Rate Dependent Forming Limit Curves[J]. International Journal of Material Forming, 2022, 15(3): 37.
[15] WANG H P, YAN Z Q, XIAO A, et al.Improvement of Flanging Accuracy with Small Springback and Service Performance of AA7075 Using High-Speed Forming[J]. Journal of Manufacturing Processes, 2024, 119: 790-805.
[16] MAKWANA R, MODI B, PATEL K.Single-Stage Single Point Incremental Square Hole Flanging of AA5052 Material[J]. Materials and Manufacturing Processes, 2023, 38(6): 680-691.
[17] CUI J J, SUN S J, AN H, et al.Effect of Ironing on Forming Characteristics in the Lorentz-Force-Driven Hole Flanging Process[J]. Journal of Materials Processing Technology, 2022, 301: 117442.
[18] LUO W Y, HUANG L, LI J J, et al.A Novel Multi- Layer Coil for a Large and Thick-Walled Component by Electromagnetic Forming[J]. Journal of Materials Processing Technology, 2014, 214(11): 2811-2819.
[19] 王紫旻, 赵淘, 马伯洋, 等. 基于多场耦合仿真的时效态铝合金电磁翻孔成形[J]. 锻压技术, 2022, 47(10): 191-197.
WANG Z M, ZHAO T, MA B Y, et al.Electromagnetic Flanging of Aging Aluminum Alloy Based on Multi- Field Coupling Simulation[J]. Forging & Stamping Technology, 2022, 47(10): 191-197.
[20] 陈明豪. AA5182铝合金异形孔电磁翻边工艺与数值模拟研究[D]. 长沙: 湖南大学, 2020: 25-28.
CHEN M H.Research on Process and Numerical Simulation of Shaped Hole Electromagnetic Flanging on AA5182 Aluminum Alloy[D]. Changsha: Hunan University, 2020: 25-28.
[21] YU H P, ZHENG Q L, WANG S L, et al.The Deformation Mechanism of Circular Hole Flanging by Magnetic Pulse Forming[J]. Journal of Materials Processing Technology, 2018, 257: 54-64.
[22] 杨澍. 管件磁脉冲侧翻边工艺研究[D]. 哈尔滨: 哈尔滨工业大学, 2011: 39-52.
YANG S.Research on Technologies of Tube Magnetic Pulse Flanging[D]. Harbin: Harbin Institute of Technology, 2011: 39-52.
[23] SU H L, HUANG L, LI J J, et al.Two-Step Electromagnetic Forming: A New Forming Approach to Local Features of Large-Size Sheet Metal Parts[J]. International Journal of Machine Tools and Manufacture, 2018, 124: 99-116.
[24] ZHANG Z X, LAI Z P, LI C X, et al.A Novel Actuator for Precise Design of the Spatial-Distributed Lorentz Force in Electromagnetic Sheet Metal Forming: Process Principle, Optimization Methodology, and Experimental Validation[J]. The International Journal of Advanced Manufacturing Technology, 2024, 131(9): 4425-4445.
[25] YAN Z Q, WEN W, WANG H P, et al.Electromagnetic Hydraulic Blanking Flanging Integrated Process[J]. Journal of Materials Processing Technology, 2025, 337: 118745.
[26] PARE V, NAGORI A, DEWANG Y.A Critical Review on Hole-Flanging Process[J]. Interactions, 2024, 245(1): 378.