Manufacturing of a branch tube with blinds for air conditioning systems of aircraft by expansion pressure of pulsed magnetic field

Aeronautical and Space-Rocket Engineering


Аuthors

Ahmed Soliman M. E.*, Kurlaev N. V.**, Shaidurov S. V.***

Novosibirsk State Technical University, 20, prospect Karla Marksa, Novosibirsk, 630073, Russia

*e-mail: axmed_soliman@corp.nstu.ru
**e-mail: kurlaev@corp.nstu.ru
***e-mail: shajdurov@corp.nstu.ru

Abstract

In the analysis of electromagnetic forming and cutting processes of aircraft parts, it is important to be able to estimate the magnetic pressure acting on the tubular workpiece. For this purpose, the RLC equivalent electrical circuit analysis has been widely used. The authors of this paper used the electromagnetic field finite element analysis to obtain a more realistic pressure distribution for the production of a branch tube with for the aircraft air conditioning system. In this study, the analysis was extended to investigate the effect of the electromagnetic forming system geometry and the workpiece material on the magnetic pressure during tube expansion. The magnetic pressure varies with the geometric parameters of the electromagnetic forming system, as predicted by the circuit analysis, the magnetic pressure decreases with the increase of the tube length. However, there is a limiting length beyond which the pressure no longer decreases. The analysis of electromagnetic forming processes consists of the electric circuit analysis and the plastic deformation of the workpiece, and these analyses are related to each other. The purpose of the electric circuit analysis is to calculate the magnetic pressure and apply it to the deformation analysis. However, in the above approaches, it was assumed that the tubular workpiece and the coil should not be long. Thus, the deformation behavior of the workpiece could only be known at the center of the pipe. The authors performed a finite element analysis of the expansion of the tube under the assumed magnetic pressure distribution, and there was no difference between the calculated and experimental results. The authors obtained a more realistic pressure distribution using the finite element analysis of the electromagnetic field and succeeded in predicting the deformation behavior of the expanding tube.
Advantages and Limitations of Using Electromagnetic Field Pressure (EMP) Tubular Expanding: 1. This method allows for high production speeds 2. Non-contact: Unlike other mechanical processes where the tool contacts the workpiece, EMP, which applies pressure, does not require lubrication, leaves no tool marks and therefore does not require post-forming cleaning. The only exception that requires lubrication is when the workpiece is moved through the die and then removed. 3. Spring Return: The material is loaded into its plastic region, resulting in permanent deformation, so that the spring return often associated with mechanical processes is virtually eliminated since there is no mechanical contact. 4. Strength: The joints made by this process are generally stronger than the parent material. 5. The EMP process provides increased ductility for some aluminum alloys due to the absence of mechanical stress and friction typically encountered in mechanical processes.

Keywords:

electromagnetic tube expansion, finite element analysis, Maxwell's differential equations, von Mises equivalent stress branch tube with blinds, tubular aircraft parts

References

  1. Golovashchenko SF, Ovchinnikov AG, Shutov RB. Methodology for design calculation of multi-turn cylindrical inductors for electromagnetic stamping. Kuznechno-shtampovochnoe proizvodstvo. 1995; (10):8–10. (In Russ.).
  2. Kurlaev NV, Akhmed Soliman ME. Impact of magnetic-pulse pressure on the spinning of sheet metal. Kuznechno-shtampovochnoe proizvodstvo. Obrabotka materialov davleniem. 2023;(2):16–20. (In Russ.).
  3. Psyk V, Risch D, Kinsey BL. et al. Electromagnetic forming a review. Journal of Materials Processing Technology. 2011;211(5):787–829. DOI: 10.1016/j.jmatprotec.2010.12.012
  4. Zhuravlev SV, Zechikhin BS, Kuz'michev RV. Analytical calculation of magnetic field in active zone of synchronous machines with permanent magnets. Aerospace MAI Journal. 2016;23(1):197-209. (In Russ.).
  5. L’Eplattenier P, Ashcraft C, Ulaca I. An MPP version of the Electromagnetism module in LS-DYNA for 3D Coupled Mechanical-Thermal-Electromagnetic simulation. 4th International Conference on High Speed Forming (March 9-10, 2010; Columbus, Ohio, USA). DOI: 10.17877/DE290R-8665
  6. Siddiqui MA, Correia JPM, Ahzi S, Belouettar S. Electromagnetic forming process: estimation of magnetic pressure in tube expansion and numerical simulation. International Journal of Material Forming. 2009;2:649–652. DOI: 10.1007/s12289-009-0431-y
  7. Durney CH, Johnson CC. Introduction to Modern Electromagnetics. New York: McGraw-Hill; 1969. 163 p.
  8. Cao Q, Du L, Li Z. et al. Investigation of the Lorentz-force-driven sheet metal stamping process for cylindrical cup forming. Journal of Materials Processing Technology. 2019;271:532–541. DOI: 10.1016/j.jmatprotec.2019.03.002
  9. Glushchenkov VA, Belyaeva IA. Distribution pipes pulsed magnetic field. The results of computer simulation. Izvestiya Samarskogo nauchnogo tsentra RAN. 2015;17(6):657–665. (In Russ.).
  10. Akhmed Soliman ME. Issledovanie deformirovaniya listovykh alyuminievykh splavov pri formoobrazovanii detalei letatel'nykh apparatov davleniem impul'snogo magnitnogo polya (Study of deformation of sheet aluminum alloys during shaping of aircraft parts by pulsed magnetic field pressure), Ph.D. thesis. Novosibirsk: NSTU; 2022. 239 p. (In Russ.).
  11. Cao Q, Li L, Lai Z. et al. Dynamic analysis of electromagnetic sheet metal forming process using finite element method. The International Journal of Advanced Manufacturing Technology. 2014;74:361–368. DOI: 10.1007/s00170-014-5939-8
  12. Zhuravlev SV, Zechikhin BS, Ivanov NS, Nekrasova YY. Analytical technique for magnetic field calculation in active zone of electric motors with superconducting excitation and armature windings. Aerospace MAI Journal. 2018;25(4):189-201. (In Russ.).
  13. Sukhachev KI, Dorofeev AS. Development and study of magnetic induction systems for micrometeorites' and cosmic particles' acceleration. Aerospace MAI Journal. 2017;24(3):134-142. (In Russ.).
  14. Buzyurkin AE, Gladkii IL, Kraus EI. Determination of parameters of the johnson-cook model for the description of deformation and fracture of titanium alloys. Prikladnaya mekhanika i tekhnicheskaya fizika. 2015;56(2):188–195. (In Russ.). DOI: 10.15372/PMTF20150219
  15. Smetannikov OYu, Zhila VV. Adaptation of the Johnson–Cook model for calculating of interim forging of deposited products in the ANSYS mechanical APDL. Master’s Journal. 2023;(2):07. (In Russ.).
  16. Abdelhafeez A, Nemat-Alla M, El-Sebaie MG. Finite element analysis of electromagnetic bulging of sheet metals. International Journal of Scientific & Engineering Research. 2012;3(2):180-186.
  17. Correia JPM, Siddiqui MA, Ahzi S. et al. A simple model to simulate electromagnetic sheet free building process. International Journal of Mechanical Sciences. 2008;50(10-11):1466–1475. DOI: 10.1016/j.ijmecsci.2008.08.008
  18. Holt DL; Babcock SG; Green SJ, Maiden CJ. The strain-rate dependence of the flow stress in some aluminum alloys. Transactions of the ASM: transactions quarterly. 1967;60:152–159.
  19. Oliveira DA, Worswick MJ. Electromagnetic forming of aluminum alloy sheet. Journal de Physique IV. 2003;110:293-298. DOI: 10.1051/jp4:20020709
  20. Oliveira DA, Worswick MJ, Finn M, Newman D. Electromagnetic forming of aluminum alloy sheet: free-form and cavity fill experiments and model. Journal of Materials Processing Technology. 2005;170(1-2): 350-362.
  21. Ahmed Soliman ME, Kurlaev NV, Shaidurov SV. Improving the Technology of Electromagnetic Compression of Branch Tube with Blinds of the Air Exchange System of Aircraft by Numerical Simulation. Aerospace MAI Journal. 2024;31(3):96-105. (In Russ.). URL: https://vestnikmai.ru/eng/publications.php?ID=182564
  22. Khaustov VM. Device for deformation of a tubular shell by the energy of a pulsed magnetic field. In: Mekhanika protsessov i mashin, Mezhvuzovskii tematicheskii sbornik nauchnykh trudov. Omsk: OmGTU; 1997. p. 77-79. (In Russ.).
  23. Manea TE, Verweij MD, Blok H. The importance of velocity term in the electromagnetic forming process. 27th General Assembly of the International Union of Radio Science (17-24 August 2002; Maastricht). p. 112–115.
  24. Geier M, Paese E, Rossi R. et al. Experimental analysis of interference-fit joining of aluminum tubes by electromagnetic forming. IEEE Transactions on Applied Superconductivity. 2020;30(4). DOI: 10.1109/TASC.2020.2972499
  25. Ouyang S, Li X, Li Ch. et al. Investigation of the electromagnetic attractive forming utilizing a dual-coil system for tube bulging. Journal of Manufacturing Processes. 2020;49:102–115. DOI: 10.1016/j.jmapro.2019.11.006

mai.ru — informational site of MAI

Copyright © 1994-2025 by MAI