Numerical Design of a Field Shaper for Magnetic Pulse Welding of Aircraft Sheet Parts

Mechanical Engineering and Machine Science


Аuthors

Ahmed Soliman M. E.*, Chinakhov D. A.**, Bataev I. A.***, Kurlaev N. V.****

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

*e-mail: axmed_soliman@corp.nstu.ru
**e-mail: chinakhov@corp.nstu.ru
***e-mail: i.bataev@corp.nstu.ru
****e-mail: kurlaev@corp.nstu.ru

Abstract

The objective of this work is to conduct a numerical study on the effective geometry of the field shaper FS in order to obtain the most suitable and most effective working area for the magnetic pressure acting on the workpiece. The novelty of this study is to simulate the magnetic pulse welding of MPW using the LS-DYNA software by the finite element method (FEM), which allows using both finite and boundary elements to solve thermo-mechanical problems during electromagnetic forming, which is confirmed by the results of the smoothed particle method (SPH).
One of the most important conditions of MPW is the formation of a jet at the collision point. To perform welding, the presence of a jet is necessary. This is the main condition for welding. Highly localized pressures created at the collision point propagate at the speed of sound. Since the collision occurs at a subsonic speed, pressures are created on the immediately approaching adjacent surfaces, sufficient to chip off a thin layer of metal from each surface and eject it as a jet. In practice, surface contaminants, oxides and impurities are removed in the jet. For bonding to occur, the two surfaces must be brought close enough to be within the range of interatomic attractive forces.
The force between two atoms consists of attractive and repulsive forces, and at a certain equilibrium distance these two forces are in equilibrium, i.e. the potential energy is at its minimum. For the two surfaces to adhere, they must be brought together within this equilibrium distance, and this requires that the surfaces be free of any oxide or other contaminant films. Theoretically, at any oblique angle of impact, if the velocity of the impact point remains subsonic, jet atomization will occur. In practice, however, a minimum angle is required to satisfy the pressure requirements, i.e. the pressure must be sufficient to exceed the dynamic elastic limit of the material to ensure deformation of the metal surfaces into a jet. To obtain a high-quality connection, it is necessary that the impact speed V_c and the contact point speed V_k are within a certain range of values in the welding window.

Keywords:

Lorentz force, magnetic pulse welding MPW, finite element analysis, single-turn coil, field shaper FS, skin effect, numerical SPH model, welding window

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