Experimental, analytical, and numerical analysis of clinched-assisted electromagnetic forming of AA1100 sheet

Abstract

AA1100 sheets have vast applications in the automobile, aerospace, heat exchangers, and nuclear industries. Clinching is a mechanical joining method using a simple tool set consisting of a punch, a die, and a punch holder. Electromagnetic forming (EMF) is a high-strain rate forming process that uses the Lorentz force to shape the workpiece. This manuscript compares the formability analysis of electromagnetic forming of the clinched and non-clinched workpieces of a thickness of 1 mm. Two sheets of the same thickness were clinched along the width. Analytical studies were conducted to calculate a magnetic field developed in the rectangular spiral coil. Furthermore, a numerical analysis was carried out using an LS DYNA explicit solver for clinching and EMF processes to verify the experimental results. © 2025, Association of American Publishers. All rights reserved.