Comprehensive analytical, experimental, and numerical analysis study of AA1100 workpiece formability and fracture in high energy electromagnetic and conventional forming process

Abstract

Electromagnetic forming (EMF) is particularly advantageous for nonferrous alloys, commonly employed to produce lightweight components for various industrial applications. AA1100 aluminum alloy is extensively utilized for its exceptional properties, including high electrical conductivity, ductility, and formability. This manuscript presents a comparative study on the performance of EMF and conventional forming methods up to the fracture limit of a 0.8 mm-thick AA1100 workpiece. A novel rectangular spiral coil design was proposed to ensure uniform stress distribution during the EMF process. Thickness distribution profiles were quantitatively assessed to validate the material flow characteristics, while the material’s deformation was evaluated using a forming limit diagram under complex strain states. Numerical analysis was carried out using LS-DYNA’s software, with mesh convergence analysis ensuring an optimal balance between accuracy and computational efficiency. The parameters involved in the EMF process, such as magnetic field, current density, Lorentz force, velocity, and workpiece dome height in conventional forming, were analyzed numerically. Microhardness tests were conducted along the thickness to evaluate strain-induced hardening and compare the workpiece’s post-formed mechanical properties. The experimental and numerical findings indicated that the dome height achieved in the EMF process was 40% and 34% higher than conventional forming. This study provides a comprehensive analytical investigation of the EMF coil design and the conventional punch-die system, offering valuable insights into the impulse and quasi-static physics governing the metal forming process. © 2025 Elsevier B.V., All rights reserved.