Title: Finite element analysis to study the shearing mechanism in punch-less electromagnetic perforation of aluminium tubes

Authors: Sagar Pawar; Ravi Valecha; Sachin D. Kore

Addresses: Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Assam, 781039, India ' Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Assam, 781039, India ' School of Mechanical Sciences, Indian Institute of Technology Goa, Ponda, Goa, 403401, India

Abstract: Electromagnetic perforation is a method of producing holes in a workpiece based on electromagnetic effect. It overcomes the disadvantages of conventional shearing processes like, the formation of burrs and slivers. Electromagnetic manufacturing is one of the well-known technologies for forming aluminium alloys. In this study, a novel approach for modelling the electromagnetic punch-less perforation has been used to study the shearing mechanism, optimum energy, and pressure required for the perforation. The complete FE analysis is conducted in two steps. Firstly, a coupled simulation model is developed in LS-DYNA software for the calculation of transient magnetic pressure generated in the process. This pressure causes the expansion of the tube, resulting in crack initiation near the die cutting edge and subsequent perforation of the tube. In the second step, to study the detailed shearing mechanism involved during the EM perforation process, obtained transient pressure is used for 2D FE analysis in Abaqus/explicit.

Keywords: finite element analysis; high strain rate shearing; electromagnetic perforation; modelling.

DOI: 10.1504/IJMPT.2020.108486

International Journal of Materials and Product Technology, 2020 Vol.60 No.1, pp.1 - 17

Accepted: 17 Feb 2020
Published online: 07 Jul 2020 *

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