An Efficient Computational Model for Magnetic Pulse Forming of Thin Structures

Electromagnetic forming (EMF) is one of the most popular high-speed forming processes for sheet metals. However, modeling this process in 3D often requires huge computational time since it deals with a strongly coupled multi-physics problem. The numerical tools that are capable of modeling this process rely either on shell elements-based approaches or on full 3D elements-based approaches. The former leads to reduced computational time at the expense of the accuracy, while the latter favors accuracy over computation time. Herein, a novel approach was developed to reduce CPU time while maintaining reasonable accuracy through building upon a 3D finite element analysis toolbox which was developed in CEMEF. This toolbox was used to solve magnetic pulse forming (MPF) of thin sheets. The problem was simulated under different conditions and the results were analyzed in-depth. Innovative techniques, such as developing a termination criterion and using adaptive re-meshing, were devised to overcome the encountered problems. Moreover, a solid shell element was implemented and tested for thin structure problems and its applicability was verified. The results of this element type were comparable to the results of the standard tetrahedral MINI element but with reduced simulation time.