Electromagnetic Metal Forming
Mission
Our mission is to team with our customers to develop electromagnetic metal forming
applications and sell those customers MAGNEPRESS®
Systems to manufacture net shape formed parts applying Electromagnetic Forming
(EMF) technology. The application of EMF will lead to the manufacture of net shaped parts
in higher volumes and a lower cost than achievable by less conventional forming processes
such as hydroforming and superplastic forming.
Description
The sections below briefly describe electromagnetic forming. For more questions and
answers, visit our MAGNEPRESS® Systems
web site.
What is Electromagnetic Metal Forming?
Electromagnetic metal forming (EMF) is the use of electromagnetic forces to form metal.
There are two very broad implementations.
- Radial forming, in which a round part such as a tube or ring is compressed or
expanded. The forming can be done either onto a die to give the tube a more complex
shape, or onto a smaller tube to swage the two tubes together.
- Sheet forming, in which a metal sheet is formed against a die to give it a more complex
shape.
- For highly detailed information, check out the references in our electromagnetic metal forming bibliography.
How does EMF work?
Briefly, EMF works by the magnetic induction effect. When a coil or solenoid is placed
near a metallic conductor and pulsed via an energy store like a capacitor bank, a magnetic
field is generated between the coil and the workpiece. If done quickly enough, the
magnetic field is excluded from penetrating into the workpiece for a short period of
time. During this time, a pressure is generated on the workpiece that is
proportional to the magnetic flux density squared. This "magnetic" pressure is
what provides the forming energy.
The energy is usually supplied to the workpiece in the form of kinetic energy. The
magnetic pressure pulse accelerates the workpiece up to a certain velocity (such as
200-300 m/s). This kinetic energy drives the material into the die, causing forming on
impact.
Why would I choose EMF over other processes?
For some applications, EMF has distinct advantages over conventional forming processes.
Any time you need to form a round part radially inward (or outward), the radial direction
of the electromagnetic forces is ideal. Examples are forming a ring-shaped part onto a
tube-shaped part, or a tube-shaped part onto a disk-shaped part. The forming causes the
two parts to swage or mechanically lock together. IAP has formed tubes and rings with
diameters ranging from about 1 inch to above 24 inches. If you use your imagination, this
describes a lot of parts.
Another reason to choose EMF is to form sheet materials in a different way than
conventional processes to improve surface quality. EMF can eliminate sheet surface
problems present in conventional metal forming methods such as stretching stringers or
marring from punches.
Reduced Springback
Electromagnetic forming is also beneficial in forming applications where spring back is
more of a concern than formability. We have developed a process called
electromagnetic stretch forming. This process allows you to form components such as
aircraft skins in the hardened condition with relatively no spring back. This has
obvious benefits with respect to product precision and quality and processing costs.
Under a Navy Small Business Innovation Research (SBIR) Phase I project for the Naval
Aviation Depot at Cherry Point NC, we were able to form 7075-T6 aluminum
directly with minimal springback eliminating the need for pre-heat treatment .
What are the cost benefits of EMF?
EMF has the highest cost savings in the following situations:
- eliminate one or more processing steps
- combine assembly or joining operations
- eliminate the need for welding (especially in aluminum alloys)
- eliminate quality problems by improving forming quality of sheet
- systems are smaller and more flexible than hydraulic presses of comparable capacity
How fast can EMF make parts?
It varies. The electromagnetic forming step takes a fraction of a second, so the
only speed limitations are 1) how fast can the EMF system recharge and fire its capacitor
banks, and 2) how fast can the material handling system move workpieces in and out of the
EMF press. Our current equipment designs are rated at 4 - 12 parts per minute. Faster
designs are possible.
Why IAP?
IAP has years of experience in developing novel applications of electromagnetic energy.
EMF technology has been in existence for over 30 years but has not seen widespread
acceptance among manufacturing engineers. We feel that this has happened as a result of a
narrow focus by earlier developers of the technology. This narrow focus has been primarily
to provide EMF equipment to low volume part producers such as aerospace companies.
Consequently, only a small amount of technology development has taken place over the last
30 years.
IAP Research is in a unique position to capture the untapped market for high volume
forming of metals such as aluminum. We will work with our customers to develop a unique
manufacturing solution centered around EMF technology. We can apply our unique
electromagnetic analysis and equipment design capabilities to develop turnkey systems to
allow you to cost effectively produce your part. If you want to evaluate the EMF process
before making in-house capital investments, we can set up a production line with our in-house capability and ship the EMF formed part directly to
your door.
Industrial Applications
IAP is currently working on numerous high volume component manufacturing applications
utilizing EMF technology. IAP has recently delivered two MAGNEPRESS® Systems. One system was
installed at the Technical University at Delft, Delft
Netherlands and is being used to fabricate prototype adavanced batteries. A second
system was installed at PMF Industries Inc. in
Williamsport, PA and is being used to fabricate heat exchangers assemblies for the food
service industry.
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