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<p>Aluminum alloy rectangular cross-section tubes are critical lightweight structural components in industries such as automotive and aerospace. However, conventional manufacturing processes for tubes with variable cross-sections are often prone to cracking or require multiple dies. This paper proposes a single-step electromagnetic forming technique to fabricate rectangular cross-section tubes precisely. The effects of the magnetic field force distribution, collision rebound, and die-fitting accuracy are analyzed via the finite element simulation. The results show that an increase in the axial distance between the tube and the coil enhances the die-fitting accuracy of the tubes, attributed to the heightened electromagnetic force at the end. However, the electromagnetic force at the straight edge region of the tube decreases as the distance between adjacent turns increases, leading to an expansion in the die-fitting gap due to insufficient forming forces. The die-fitting gap of the tube initially decreases and then increases with an increase in the discharge voltage. The most optimal results were achieved when the discharge voltage was set at 6000&#xa0;V, resulting in the complete fitting of the tube to the die. The results hold significant value in advancing the application of electromagnetic forming for tubes.</p>

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Single-step electromagnetic forming for high-precision fabrication of aluminum alloy rectangular cross-section tubes

  • 期刊论文

  • 发表日期：

    2025年3月7日

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  • Xiaoming Sun,
  • Nan Zhou,
  • Xuan Chen,
  • Zhuoxing Yu,
  • Chuan Zhou,
  • Xiaohui Cui

摘要

Aluminum alloy rectangular cross-section tubes are critical lightweight structural components in industries such as automotive and aerospace. However, conventional manufacturing processes for tubes with variable cross-sections are often prone to cracking or require multiple dies. This paper proposes a single-step electromagnetic forming technique to fabricate rectangular cross-section tubes precisely. The effects of the magnetic field force distribution, collision rebound, and die-fitting accuracy are analyzed via the finite element simulation. The results show that an increase in the axial distance between the tube and the coil enhances the die-fitting accuracy of the tubes, attributed to the heightened electromagnetic force at the end. However, the electromagnetic force at the straight edge region of the tube decreases as the distance between adjacent turns increases, leading to an expansion in the die-fitting gap due to insufficient forming forces. The die-fitting gap of the tube initially decreases and then increases with an increase in the discharge voltage. The most optimal results were achieved when the discharge voltage was set at 6000 V, resulting in the complete fitting of the tube to the die. The results hold significant value in advancing the application of electromagnetic forming for tubes.