Buiron, N.

Rachik, M.

Sapanathan, T.

Yang, K.

Eldorado - Ressourcen aus und für Lehre, Studium und Forschung

Insight into the realistic behaviours of magnetic pulse forming and welding processes using numerical simulations T. Sapanathan1, K. Yang1,N. Buiron1 and M. Rachik1 1 Sorbonne universités, Université de technologie de Compiègne, CNRS, laboratoire Roberval, UMR – 7337, Centre de recherche Royallieu, CS 60 319, 60 203 Compiègne cedex Introduction Model 1 Model 2 Model 3 Ring expansion Introduction: Project COILTIM • Produce efficient welding of similar / dissimilar metal pairs • Joint quality analysis with process parameters • Joint quality analysis of the effect of metal dissimilarity • Modeling and simulation of the MPF/MPW • Feasibility study and development of processing tools   2 [MPF/MPW: Magnetic Pulse Forming / Magnetic Pulse Welding] Outline • Methods about the EM numerical modelling, investigating the influence of the cylindrical rod in a MPW • Main focuses on the numerical modelling of MPW • EM component • Interfacial behaviour • Contact behaviour • Field shaper effect in forming and welding • Change in force direction, during MPF/MPW • Development of negative velocity and spring back effect in ring expansion process • Identification of material models for MPF/MPW processes Introduction Model 1 Model 2 Model 3 Ring expansion 3 [EM: Electromagnetic; MPF: Magnetic Pulse Forming; MPW: Magnetic Pulse Welding ] Introduction Model 1 Model 2 Model 3 Ring expansion Preliminary models: Tube compression with and without rod using helix coils 4 Tube without cylinder rod model Tube with cylinder rod model Model 1 Model 1 Model 2 Model 3 Ring expansion Input current used in those preliminary models (I. Henchi et al, 10th International LS-Dyna  User Conference) 5 0 20000 40000 60000 80000 100000 120000 140000 160000 0.00E+00 1.00E-06 2.00E-06 3.00E-06 4.00E-06 5.00E-06 Current (A) Time (s) Introduction Model 1 Model 2 Model 3 Ring expansion Material Model (T. Mabrouki et al. 2008, Int. Journal of Machine tools & Manufacture) 6 Introduction Model 1 Model 2 Model 3 Ring expansion Electromagnetic properties of material  • σ of the work piece: Aluminum alloy – 30% IACS (1.74 x 104 S/mm) • Copper helix coil – 70% IACS (4.06 x 104 S/mm) • Steel coil – 7% IACS (4.06 x 103 S/mm) • µr = µ / µ0, for copper alloy, steel and air are considered to be ~ 1 • However this µr may significantly vary with the type of steel  7 Introduction Model 1 Model 2 Model 3 Ring expansion Coil geometry and non axisymmetric deformation Model Geometry Pressure distribution Effective plastic strain distribution  8 Introduction Model 1 Model 2 Model 3 Ring expansion Model with one turn symmetric  coil  9 Introduction Model 1 Model 2 Model 3 Ring expansion Material and other parameters • Core and solid made from aluminium A2024 – T351 • One turn coil with axis-symmetric geometry used and a symmetric current flow expected    10 Expected a symmetric current flow 0.0E+00 5.0E+05 1.0E+06 1.5E+06 2.0E+06 2.5E+06 3.0E+06 0.0E+00 2.0E-06 4.0E-06 Input current (A) Time (s) Introduction Model 1 Model 2 Model 3 Ring expansion A A Section A-A 11 The multi-layered mesh to capture the gradient of the eddy current Introduction Model 1 Model 2 Model 3 Ring expansion Investigation of nodal velocity  12 Introduction Model 1 Model 2 Model 3 Ring expansion Model without the cylinder rod  13 Introduction Model 1 Model 2 Model 3 Ring expansion Nodal velocity from the top edge 0.00E+00 5.00E+04 1.00E+05 1.50E+05 2.00E+05 2.50E+05 3.00E+05 3.50E+05 4.00E+05 4.50E+05 0.00E+00 1.00E-06 2.00E-06 3.00E-06 4.00E-06 5.00E-06 Velocity (mm/s) Time (seconds) Z= 0.0 mm_top edge Z= 0.5 mm from top edge Z= 1.0 mm from top edge Z= 1.5 mm from top edge Z= 2.0 mm from top edge 14 0.0E+00 5.0E+05 1.0E+06 1.5E+06 2.0E+06 2.5E+06 3.0E+06 0.0E+00 2.0E-06 4.0E-06 Current (A) Time (s) Introduction Model 1 Model 2 Model 3 Ring expansion With Solid rod in the model, but without contact 15 Introduction Model 1 Model 2 Model 3 Ring expansion Nodal velocity from top edge for the model with the cylinder rod 0.0E+00 5.0E+04 1.0E+05 1.5E+05 2.0E+05 2.5E+05 3.0E+05 3.5E+05 4.0E+05 0.0E+00 1.0E-06 2.0E-06 3.0E-06 4.0E-06 5.0E-06 Velocity (mm/s) Time (Seconds) Z= 0.0 mm_top edge Z= 0.5 mm from top edge Z= 1.0 mm from top edge Z= 1.5 mm from top edge Z= 2.0 mm from top edge 16 0.0E+00 5.0E+05 1.0E+06 1.5E+06 2.0E+06 2.5E+06 3.0E+06 0.0E+00 2.0E-06 4.0E-06 Current (A) Time (s) Introduction Model 1 Model 2 Model 3 Ring expansion Comparison of velocity  without and with the cylinder rod 0.0E+00 5.0E+04 1.0E+05 1.5E+05 2.0E+05 2.5E+05 3.0E+05 3.5E+05 4.0E+05 4.5E+05 0.0E+00 1.0E-06 2.0E-06 3.0E-06 4.0E-06 5.0E-06 6.0E-06 Velocity (mm/s) Time (s) top edge - without cylinder rod top edge - with cylinder rod 2 mm below top edge - without cylinder model 2 mm below top edge - with the cylinder rod 17 0.0E+00 5.0E+05 1.0E+06 1.5E+06 2.0E+06 2.5E+06 3.0E+06 0.0E+00 2.0E-06 4.0E-06 Current (A) Time (s) Introduction Model 1 Model 2 Model 3 Ring expansion Comparison of plastic strain  without and with the cylinder rod 18 Plastic strain without the cylinder rod            Plastic strain with the cylinder rod                     Maximum : 7.54%                                          Maximum: 6.47% Introduction Model 1 Model 2 Model 3 Ring expansion Welding and contact models • Mechanical + Electromagnetic contact algorithms used in these models  19 Introduction Model 1 Model 2 Model 3 Ring expansion von Mises stress distribution (MPa) Fieldshaper slot side Opposite side 20 Introduction Model 1 Model 2 Model 3 Ring expansion Effective stress at the beginning of the impact (MPa) Fieldshaper slot side Opposite side 21 Introduction Model 1 Model 2 Model 3 Ring expansion von Mises stress and Lorentz force (N/mm3) 22 Introduction Model 1 Model 2 Model 3 Ring expansion direction of force without the solid rod, in a tube only model 23 Introduction Model 1 Model 2 Model 3 Ring expansion Eddy current changes in welding model, just Before the impact at 11µs 24 Introduction Model 1 Model 2 Model 3 Ring expansion Eddy current changes in welding model, at 5µs and just before the impact at 11µs 25 At 5µs Introduction Model 1 Model 2 Model 3 Ring expansion Eddy current changes in flyer tube 26 Just after impact 13µs Just before  impact 11µs Onset of  impact  12µs After impact 14µs Introduction Model 1 Model 2 Model 3 Ring expansion Average radial Lorentz force near free edge and 2.5mm below the free edge 27 -1000 -500 0 500 1000 1500 2000 2500 3000 3500 4000 0 5 10 15 20 25 Radial Lorentz force (N/mm3) Time (µs) On free edge 2.5mm below the free edge 0 500 0 20 Current (kA) Time (µs) Source Current Introduction Model 1 Model 2 Model 3 Ring expansion 28 Ring expansion simulation test 3D model in LS-DYNA A (MPa) B (MPa) C n 324 114 0.42 0.002 Johnson-Cook parameters used for ring (AA6061-T6) schematic cross-section(Initial state) Introduction Model 1 Model 2 Model 3 Ring expansion Plastic strain in the ring expansion 29 Introduction Model 1 Model 2 Model 3 Ring expansion Analysis of process parameters  30 Introduction Model 1 Model 2 Model 3 Ring expansion Spring back effect 31 Stress here is denoted as σ1 Ring radius here is denoted as ri Max spring back radius: Vibration frequency: Max spring back velocity: Introduction Model 1 Model 2 Model 3 Ring expansion Identification of suitable material models for MPF/MPW 32 a) Johnson-Cook model:   b) Cowper-Symonds model:  •       is the von Mises stress in quasi-static deformations. It could be determined by quasi-static tensile test;  •            is the viscoplasticity factor. Two most common models:   Viscoplasticity: [MPF/MPW: Magnetic Pulse Forming / Magnetic Pulse Welding] Introduction Model 1 Model 2 Model 3 Ring expansion Diagram of identification steps 33 Reference measurements Simulation by LS-DYNA® Output measurements Set constitutive model values Calculate the difference  Minimize the difference by SiDoLo® [SiDoLo®: Software toolbox used for identification] Introduction Model 1 Model 2 Model 3 Ring expansion Result for Johnson-Cook model  34 Target Start Result 0.0335 0.09 0.033503 Determination of C, with Target Start Result 0.0335 0.005 0.033383 Introduction Model 1 Model 2 Model 3 Ring expansion Result for Cowper-Symonds model  35 Target Start Result C 20000 10000 19778.6 p 4.0 5.0 4.0 Determination of C and p, with Conclusions Conclusions 36 • Predictive numerical models were developed for MPF/MPW • The changes in the deformation behaviours with additional components were investigated • Fieldshaper slot effect was investigated • Change in Lorentz force direction and eddy current were also studied • Changes in electromagnetic field significantly influence the deformation behaviours • Vibration due to spring back was studied in a ring expansion test • Numerical models developed for the purpose of identification of material’s constitutive models in MPF/MPW [MPF/MPW: Magnetic Pulse Forming / Magnetic Pulse Welding] Authors would like to thank the “Région Picardie” and “Le Fonds européen de développement régional (FEDER)” for their financial support and “Plateforme Innovaltech” for assisting in the development of the numerical model    Thank you for your attention Insight into the realistic behaviours of magnetic pulse forming and welding processes using numerical simulations  Insight into the realistic behaviours of magnetic pulse forming and welding processes using numerical simulations  

Insight into the realistic behaviours of magnetic pulse forming and welding processes using numerical simulations

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Insight into the realistic behaviours of magnetic pulse forming and welding processes using numerical simulations

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