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<p>Electromagnetic forming (EMF) is applied to the hole flanging of aluminum alloys due to its significant advantages in improving forming limits and suppressing springback. However, a major challenge for this application lies in the conformal coil structure’s difficulty in achieving acceptable die gap conformity and deformation control. To address this, a loosely coupled finite element model was developed in Ansys to simulate the EMF hole flanging process. Utilizing this finite element model (FEM), the Plackett–Burman design (PBD) method identified 10 key variables (out of 18 structural coil parameters) that most significantly impact the distribution of electromagnetic force. Subsequently, the optimization process employed the Optimal Latin Hypercube Sampling (OLHS) technique, an Elliptic Basis Function (EBF) neural network model, and the Non-Dominated Sorting Genetic Algorithm II (NSGA-II) to obtain sensitivity analysis results, a Pareto solution set, and the optimal equilibrium solution. Sensitivity analysis revealed that the coil width parameter exerts the most substantial influence on thinning rate and die gap conformity. The optimized coil design generated electromagnetic forces that were strengthened at the flange edge and distributed more uniformly across the deformation zone during flanging. This resulted in increased acceleration magnitudes and enhanced deformation. For the formed parts, the maximum die gap decreased from 2.65 to 0.41&#xa0;mm, and the axial height difference diminished from 1.30 to 0.26&#xa0;mm. This optimized force and deformation control yielded flanged parts with significantly improved conformity to industrial product specifications. Moreover, the maximum thinning rate was reduced from 27.5 to 21.45%.</p>

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Sensitivity analysis and multi-objective optimization of electromagnetic elliptical hole flanging coil structures

  • 期刊论文

  • 发表日期：

    2025年9月4日

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  • Yangfan Qin,
  • Yuefan Jiang,
  • Guangyao Li,
  • Hao Jiang,
  • Junjia Cui

摘要

Electromagnetic forming (EMF) is applied to the hole flanging of aluminum alloys due to its significant advantages in improving forming limits and suppressing springback. However, a major challenge for this application lies in the conformal coil structure’s difficulty in achieving acceptable die gap conformity and deformation control. To address this, a loosely coupled finite element model was developed in Ansys to simulate the EMF hole flanging process. Utilizing this finite element model (FEM), the Plackett–Burman design (PBD) method identified 10 key variables (out of 18 structural coil parameters) that most significantly impact the distribution of electromagnetic force. Subsequently, the optimization process employed the Optimal Latin Hypercube Sampling (OLHS) technique, an Elliptic Basis Function (EBF) neural network model, and the Non-Dominated Sorting Genetic Algorithm II (NSGA-II) to obtain sensitivity analysis results, a Pareto solution set, and the optimal equilibrium solution. Sensitivity analysis revealed that the coil width parameter exerts the most substantial influence on thinning rate and die gap conformity. The optimized coil design generated electromagnetic forces that were strengthened at the flange edge and distributed more uniformly across the deformation zone during flanging. This resulted in increased acceleration magnitudes and enhanced deformation. For the formed parts, the maximum die gap decreased from 2.65 to 0.41 mm, and the axial height difference diminished from 1.30 to 0.26 mm. This optimized force and deformation control yielded flanged parts with significantly improved conformity to industrial product specifications. Moreover, the maximum thinning rate was reduced from 27.5 to 21.45%.