Forming the inner flange of a rib by pulsed-magnetic field pressure

Abstract Electromagnetic flanging is a hole-protrusion of parts, a potential technology for forming sheet aluminum metal, provides rigidity, allows positioning and fixing. This paper describes the behavior of a workpiece formed by an electromagnetic flanging, in which the initial blank of annealed aluminum alloy D16AM with a circular precut hole is formed into the first part of the inner flanging (as the first operation of manufacturing a part of the rib). The purpose of this article is to assess the ability of electromagnetic shaping to produce flanges for aircraft components and to study the forming process using numerical simulation. Design of electromagnetic flanges with some elementary geometric shapes, the purpose of which is to clarify a few geometric defects encountered and to propose some solutions. The numerical model of this part was developed in the LS-DYNA computing environment. An example of the numerical simulation of electromagnetic forming of the inner flange of a rib with the obtained shape of the workpiece mesh using a clamp is given. To avoid corrugation at the corner of the workpiece, the magnetic force was increased by reducing the area of the coil adjacent to the corner.