Electromagnetic forming (EMF) is a high strain-rate forming method where a pulsed
electromagnetic force is applied to a conductive metallic workpiece. To improve the
performance of the EMF system, the current problems which restrict its extensive
application have been analyzed. To this end, a space-time-controlled EMF technology
with multi-stage and multi-direction coils system has been developed. In our new EMF
system, the magnetic field generated by driving coils is much higher than in conventional
EMF due to introducing design methods developed for non-destructive pulsed high field
magnets. This technology enables the forming of complex, large-scale sheets and tubes
that may be difficult to deform by conventional methods, as well as controlling particular
properties of the work pieces

Ding, Hongfa

Han, Xiaotao

Huang, Liang

Li, Jianjun

Li, Liang

Liu, Lin

Mo, Jianhua

Peng, Tao

Qiu, Li

Zhou, Zhongyu

Eldorado - Ressourcen aus und für Lehre, Studium und Forschung

April, 25, 2012       Dortmund, Germany Space-Time-Controlled Multi-Stage Pulsed Magnetic Field Forming Liang Li1， Xiaotao Han1，Li Qiu1， Zhongyu Zhou1，Tao Peng1, Hongfa Ding1, Jianjun Li2， Lin Liu2，Jianhua Mo2，Liang Huang2  1. Wuhan National High Magnetic Field Center (WHMFC), 2. College of Materials Science and Engineering , Huazhong University of Science & Technology (HUST), Wuhan, 430074, P.R.China 2 April, 25, 2012            ICHSF2012, Dortmund, Germany Outline Introduction of WHMFC Concept of Space-Time-Controlled Multi-Stage Pulsed Magnetic Field （Stic-Must-PMF）Forming and Manufacturing Technology Recent progress of Stic-Must-PMF at Pulsed Magnetic Field Forming Conclusion 3 April, 25, 2012            ICHSF2012, Dortmund, Germany ØBeijing ØShanghai ØWuhan Where is WHMFC? 4 April, 25, 2012            ICHSF2012, Dortmund, Germany  The capital of Hubei province,  The most populous city in central China with a population of approximately 9,100,000 people.   Big joint center of rail ways, water ways and the airlines  22 Colleges and universities   8 national colleges and universities, 14 public colleges and universities.            Wuhan City 5 April, 25, 2012            ICHSF2012, Dortmund, Germany Huazhong University of Science and Technology One of leading universities of the Ministry of Education in China.  2 National laboratory 4 National Leading Laboratories, 5 National Engineering Research Centers,  27 Leading Laboratories of Ministerial and Provincial Level. 29 key subjects are national level and 28 key subjects are ministerial and provincial level.   11 full academicians and 5 part-time academicians of the CAS and CAE. Full-time students > 50, 000   14, 000 MSs and 5, 300 Ph.Ds . Faculty members >10,000,   1016 full professors   1, 348 associate professors.  Area covers: 4,689,323 square meters 6 April, 25, 2012            ICHSF2012, Dortmund, Germany Wuhan National High Magnetic Field Center 7 April, 25, 2012            ICHSF2012, Dortmund, Germany The Structure of the Pulsed Field Facility at WHMFC 3He制冷机（300mK）光  源磁光特性科学实验测试系统电容器模块6(1MJ)电容器模块7(1MJ)电容器模块5(1MJ)电容器模块2(1MJ)电容器模块8(1MJ)电容器模块4(1MJ)氦液化器和超流氦系统（1.4K－4.2K）3He-4He稀释制冷机（30mK）高静压10kV母线公用及辅助设施主 监 控 系 统公用及辅助设施监控系统科学实验测试系统监控系统电容器模块9(1MJ)电容器模块10(1MJ)实验筛选与标定室超导磁体压力效应科学实验测试系统极低温科学实验测试系统脉冲磁体测试室待测磁体调速系统液氮储槽（77K）励磁系统GM土建工程监控系统长短合成脉冲磁体磁特性科学实验测试系统电容器模块3(1MJ)电容器模块1(1MJ)电容器模块11(1MJ)长脉冲磁体电输运科学实验测试系统短脉冲磁体电容器模块12(0.5MJ)电容器模块13(0.5MJ) 14.8 MJ/25kV capacitor bank 100MVA/100MJ pulse generator SP magnets LP magnets LSP magnets SC magnets test magnets  Transport  cell laser Magnetiz ation cell magneto- optics cell ESR High Pressure Other Applications PPMS& SQUID 4He  .5  - .  LN2  k 3He  00mK 3He-4He 5  mk 8 April, 25, 2012            ICHSF2012, Dortmund, Germany The Structure of the Pulsed Field Facility at WHMFC 3He制冷机（300mK）光  源磁光特性科学实验测试系统电容器模块6(1MJ)电容器模块7(1MJ)电容器模块5(1MJ)电容器模块2(1MJ)电容器模块8(1MJ)电容器模块4(1MJ)氦液化器和超流氦系统（1.4K－4.2K）3He-4He稀释制冷机（30mK）高静压10kV母线公用及辅助设施主 监 控 系 统公用及辅助设施监控系统科学实验测试系统监控系统电容器模块9(1MJ)电容器模块10(1MJ)实验筛选与标定室超导磁体压力效应科学实验测试系统极低温科学实验测试系统脉冲磁体测试室待测磁体调速系统液氮储槽（77K）励磁系统GM土建工程监控系统长短合成脉冲磁体磁特性科学实验测试系统电容器模块3(1MJ)电容器模块1(1MJ)电容器模块11(1MJ)长脉冲磁体电输运科学实验测试系统短脉冲磁体电容器模块12(0.5MJ)电容器模块13(0.5MJ) 14.8 MJ/25kV capacitor bank 100MVA/100MJ pulse generator SP magnets LP magnets LSP magnets SC magnets test magnets  Transport  cell laser Magnetiz ation cell magneto- optics cell ESR High Pressure Other Applications PPMS& SQUID 4He  .5  - .  LN2  k 3He  00mK 3He-4He 5  mk 9 April, 25, 2012            ICHSF2012, Dortmund, Germany 200/8c 14 C 80 Dual stage 200 26 C 60 2250/100b 22 Ga 50 Long pulse 15 12 C 80 20 14 C 70 30 22 C 60 65 34 C 50 Short pulse Pulse duration (ms) Bore (mm) Power type Field (T) Parameters of pulsed Magnet and Field waveform The Objectives 10 April, 25, 2012            ICHSF2012, Dortmund, Germany 200/8c 14 C 80 Dual stage 200 26 C 60 2250/100b 22 Ga 50 Long pulse 15 12 C 80 20 14 C 70 30 22 C 60 65 34 C 50 Short pulse Pulse duration (ms) Bore (mm) Power type Field (T) Parameters of pulsed Magnet and Field waveform 时间(ms)磁场(T)0 20 40 60020406080    PMT50S  PMT60S  PMT70S  PMT80S  The Objectives 11 April, 25, 2012            ICHSF2012, Dortmund, Germany 200/8c 14 C 80 Dual stage 200 26 C 60 2250/100b 22 Ga 50 Long pulse 15 12 C 80 20 14 C 70 30 22 C 60 65 34 C 50 Short pulse Pulse duration (ms) Bore (mm) Power type Field (T) Parameters of pulsed Magnet and Field waveform 时间(ms)磁场(T)0 20 40 60020406080    PMT50S  PMT60S  PMT70S  PMT80S  0.0 0.5 1.0 1.5 2.00102030450   Bin Bout Bsum时间（s）磁场（T）The Objectives 12 April, 25, 2012            ICHSF2012, Dortmund, Germany 200/8c 14 C 80 Dual stage 200 26 C 60 2250/100b 22 Ga 50 Long pulse 15 12 C 80 20 14 C 70 30 22 C 60 65 34 C 50 Short pulse Pulse duration (ms) Bore (mm) Power type Field (T) Parameters of pulsed Magnet and Field waveform 时间(ms)磁场(T)0 20 40 60020406080    PMT50S  PMT60S  PMT70S  PMT80S  0.0 0.5 1.0 1.5 2.00102030450   Bin Bout Bsum时间（s）磁场（T）The Objectives 10 20 30 4 50 60 70 80 90 100 110 12010203040506070809  Magnetic field (T)Time (ms)13 April, 25, 2012            ICHSF2012, Dortmund, Germany Power Supplies Completed the construction of the  14.8MJ/25kV capacitor bank, of which two modules have been pulsed over 3000 shots with no problem. 14 April, 25, 2012            ICHSF2012, Dortmund, Germany Power Supplies Pulsed-generator has been installed and in operation  for 3 years with no fault. ØMotor： Ø   Capacity：1417kW Ø   Rated input voltage：10kV Ø   Rated speed：713rpm ØGenerator： Ø   Capacity：100MVA Ø   Energy output：100MJ Ø   Rotor speed：495－713rpm Ø   Rated output voltage：6.9kV 0.0 0.5 1.0 1.5 2.001020304050   Bin Bout Bsum时间（s）磁场（T）15 April, 25, 2012            ICHSF2012, Dortmund, Germany  Magnets 0 10 20 30 40 50 60 70 0 1 2 3  Radial  Hoop  Axial  von Mises   Stress (GPa) Radius (mm) 0 1 2 3 4 100 150 200 250 300 350 400 450 500 0.05 ms 2.5 ms 5 ms 10 ms 20 ms Temp (K) R (cm) Thermal Distribution Stress Distribution       A pulsed magnet designing software has been developed which solves the coupled electromagnetic-mechancial-thermal model with a user friendly interfaceand has been widely used by other high magnetic field labs. 16 April, 25, 2012            ICHSF2012, Dortmund, Germany  Magnets 0 10 20 30 40 50 60 70 0 1 2 3  Radial  Hoop  Axial  von Mises   Stress (GPa) Radius (mm) 0 1 2 3 4 100 150 200 250 300 350 400 450 500 0.05 ms 2.5 ms 5 ms 10 ms 20 ms Temp (K) R (cm) Thermal Distribution Stress Distribution       A pulsed magnet designing software has been developed which solves the coupled electromagnetic-mechancial-thermal model with a user friendly interfaceand has been widely used by other high magnetic field labs. 17 April, 25, 2012            ICHSF2012, Dortmund, Germany Magnets  Coil Winding machine has been in service since 2009. 18 April, 25, 2012            ICHSF2012, Dortmund, Germany Magnets Short pulse magnet made of soft copper successfully reached 78 T non-destructively  Completed 8 short-pulsed magnets intensity ranged from 50T to 78T.          19 April, 25, 2012            ICHSF2012, Dortmund, Germany Magnets 10 20 30 40 50 60 70 80 90 100 110 1200102030405060708090  Magnetic field (T)Time (ms) Dual stage pulsed magnet reached 83 T non-destructively 20 April, 25, 2012            ICHSF2012, Dortmund, Germany Monitoring and the Control system  Completed the hardware & software installation of the controlling system; The security & warning system and monitoring system are in service. The whole system is in operation now. 21 April, 25, 2012            ICHSF2012, Dortmund, Germany Developed 7 measurement stations Magneto-Optics Transport and Magnetization Extremely Low Temperature system ESR system 22 April, 25, 2012            ICHSF2012, Dortmund, Germany Applications of pulsed high magnetic field at WHMFC  Pulsed High Magnetic Field Facility  Electromagnetic Forming  Magnetic refrigiration  Eddy current breaking  Post magnitization 23 April, 25, 2012            ICHSF2012, Dortmund, Germany Compact Pulsed High Magnetic Field Facility Experimental setup Applications of High Magnetic Field Technology Experimental result  Automatic charge-discharge operation repeatedly under 50 T high field.  Integrated pulsed magnet, pulsed power source and corresponding control system as well as its interface.  Can be applied as a research device independently as well as integrated into other facility as an optional component.   Compact size, Friendly interface and low cost. 24 April, 25, 2012            ICHSF2012, Dortmund, Germany Appling to form small, thin-walled   workpieces and local forming only Requirements for    large deformation   parts forming  Single coil structure, the Lorenz force on the workpiece decreases rapidly. Limitations of the conventional electromagnetic forming Development trend of the electromagnetic forming Development Trend of the Electromagnetic Forming Higher magnetic field strength Wider magnetic field region More flexible timing control The magnetic field strength is normally low（<10T）, the energy of the power supply is mostly less than 100KJ. 25 April, 25, 2012            ICHSF2012, Dortmund, Germany 1000kJ single module power Magnetic field shape measured in the two-stage 83T pulsed magnet Multi-module Timing Control system WHMFC has owned key technologies for Stic-Must-PMF   A magnetic field intensity of 83T was achieved by using two-stage coil structure, multi-module power supply and timing control technology . 83T two-stage pulsed magnet Foundation for Stic-Must-PMF  Ultra-high field pulsed magnet  High density pulsed power source  Accurate magnetic field space-time control 26 April, 25, 2012            ICHSF2012, Dortmund, Germany Funded as  the National Basic Research Program of China (973 Preject) by the Chinese ministry of Science and Technology, total funding budget is 38 M Chinese Yuan (4 M Euro); multiple space-time HPMF Schematic illustration of the  multiple space-time PHMF deep drawing forming system Concept of Stic-Must-PMF Forming Technology Coil 1 Coil 2 Coil 3 Coil 4 Power 1 Power 2 Power 3 Power 4 Timing Control multiple powers multiple coils multi-scale, multi-stage and multi-direction electromagnetic force field large-scale and complex sheet and tube parts forming 27 April, 25, 2012            ICHSF2012, Dortmund, Germany Coils miniaturization and arrays design Ultra-fast pulsed high power source Potential Applications  large-scale sheet Plastic flow forming large-scale panel  internal stress adjustment and control abnormity tube Local flow and interface connection Stic-Must -PMF Multiple coils Combination long-pulse coil with short-pulse coil Multiple power sources High strength coil Continuous discharge coil 28 April, 25, 2012            ICHSF2012, Dortmund, Germany How to generate the Space-Time-Controlled Multi-Stage pulsed magnetic field？ Challenges to the Forming Equipment                          Multi-stage and multi-direction magnetic field distribution Electromagnetic coupling among multi coils     (Magnetic force among multi coils) Complex Interrelation between the      magnetic field and materials    (Skin effect、magneto-resistance effect)  Difficulties for optimal design of coils strength and arrangement 29 April, 25, 2012            ICHSF2012, Dortmund, Germany Coupled analysis of electro-magnetic field, stress field and heat field Technological Difficulties System integration Optimal design of magnetic field, coil structure and spatial arrangement  Design of modular power system and timing control system Theoretical analysis Structural design  Optimal design of magnetic field, coil structure and spatial arrangement   Difficulties  Coupled analysis of electro-magnetic field, stress field and heat field  Design of modular power system and timing control system  iffi lti   30 April, 25, 2012            ICHSF2012, Dortmund, Germany Research Contents The magnetic field penetration, eddy current distribution and the energy conversion law involved in  the forming of complex structures Research content The effective regulation of the magnetic field and electromagnetic force for the multi-stage and multi-direction PHMF system Modeling and design criteria for the multi-stage and multi-direction PHMF system Building the experimental platform of multi-stage and multi-direction HPMF system for large-scale and complex work pieces Expected  breakthrough Revealing the laws of magnetic field and electromagnetic force in multiple-coil system Breaking through technical bottleneck of Stic-Must-PMF forming and manufacturing system Expected      results  Magnetic flux density：0~50T；  Power energy：<1000 kJ；  Multi-stage control：>3;  Auxiliary heating, edge pressing and assembling integration. Equipment  Characteristic Design theory and method of space-time-controlled  multi-stage electromagnetic force 31 April, 25, 2012            ICHSF2012, Dortmund, Germany Structure optimization design    of electromagnetic coils Modular power design Timing logical control Experiment test platform Experimental Verification of       process parameters Model calibration and     modification  Magnetic field distribution Forming force distribution  Energy conversion  Work-piece motion law 标准实验 Theoretical analysis Major facility prototype Electromagnetic parts design Forming concept Technical Solution   Research Program 32 April, 25, 2012            ICHSF2012, Dortmund, Germany  WHMFC has built a 2mF/8kV/20kA electromagnetic forming equipment, and researched the electromagnetic forming, hole flanging, and cutting using the equipment. EMF simulations and Formed Workpieces Electromagnetic Forming Equipment Recent progress at Pulsed Magnetic Field Forming Coils Optimization  1. Electromagnetic Forming Equipments 33 April, 25, 2012            ICHSF2012, Dortmund, Germany Recent progress at Pulsed Magnetic Field Forming  R ight  figure shows that the aluminium sheet workpiece after free bulging exists plastic flow in the electromagnetic forming process, which the whole sheet flowed into the die.  Sheet thickness is 1 mm, sheet diameter is 140 mm, the die diameter is 100 mm.   Plastic flow is very important to deep drawing  1.102 1.006 0.926 0.928 0.918 0.914 0.848 0.824 0.796 0.784 2. Plastic Flow in the Electromagnetic Forming Process 34 April, 25, 2012            ICHSF2012, Dortmund, Germany Conclusion A new high field pulsed magnetic field facility is under development with 14.8 MJ/ 25 kV capacitor bank and 100 MJ/ 100 MVA pulse generator as its power supplies.  Pulsed magnets made of soft copper has successfully reached 78 T, Dual stage pulsed magnet reached 83 T non-destructively; A new concept of Space-Time-Controlled Multi-Stage Pulsed Magnetic Field forming has been proposed;  The Stic-Must-PMF forming project has been funded as  the National Basic Research Program of China (973 Program, 2011CB012800) by the Chinese ministry of Science and Technology, total funding budget is 38 M Chinese Yuan (4 M Euro); The objective of the project is the development a prototype electromagnetic forming facility that can do sheet forming,surface work hardening, internal stress shape adjustment and composites tube forming. 35 谢谢！ 

Space-Time-Controlled Multi-Stage Pulsed Magnetic Field Forming

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Space-Time-Controlled Multi-Stage Pulsed Magnetic Field Forming

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Eldorado - Ressourcen aus und für Lehre, Studium und Forschung