Numerical study of the stress-strain state in designing a field shaper for magnetic-pulse welding of the sheet metal parts
Authors: Ahmed Soliman M.E., Anisimov A.G.
Published in issue: #8(164)/2025
Category: Mechanics | Chapter: Mechanics of Deformable Solid Body
Objective of this research lies in design and development of an improved field shaper for magnetic-pulse welding of the thin sheet metal blanks. The paper uses the finite element method for a comprehensive analysis of the electromagnetic and mechanical processes interaction. Results of the study show that the shaper optimized design ensures the maximum magnetic field induction of 45 T and the peak Lorentz force of 6.9·105 N/mm3. They indicate that at the plate impact velocity of up to 600 m/s and the oblique impact angle of 20°, high-quality welded joints with the contact length of 10 mm are formed. The paper pays particular attention to the induction mechanism of the secondary currents appearing when the primary current flows through the coil and creating a concentrated electromagnetic field that affects the CP-Ti titanium and Cu110 copper blanks in welding. Based on the research conducted, practical recommendations are presented for selecting the optimal geometric characteristics and materials in manufacture of the field shapers. The paper indicates that brass shapers used in the magnetic pulse welding demonstrate the best combination of electrical conductivity and mechanical strength indicators, which ensures efficient operation of the entire system. When working with the titanium blanks, it is recommended to use shapers with the increased working area providing a more intense effect. At the same time, shapers of a compact design are sufficient in machining the copper blanks. The main design parameters include the curvature radius matched to the coil configuration and the calculated wall thickness, which should simultaneously ensure mechanical strength of the structure and efficient redistribution of the electromagnetic field. The proposed solutions ensure stable quality of joining the dissimilar metals, and contribute to development of the magnetic-pulse welding technology. The results obtained are of high practical importance in the electrical and mechanical engineering industries, facilitate an increase in reliability and reproducibility of the critical structures welding, and make a significant contribution to development of the magnetic-pulse welding technology.
EDN YCUITO
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