Attractive electromagnetic force flanging method for small tube fittings with magnetic field shaper
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摘要: 针对微小铝合金管件电磁翻边工艺，现有方法将驱动线圈置于管件端部外侧，利用双频电流法产生吸引式电磁力实现翻边。然而其翻边能力不强，基于此提出一种带集磁器的吸引式电磁力翻边方法。在现有方法基础上引入集磁器，利用其能够改变磁场位形的特点，优化电磁力分布并增大轴向电磁力，达到增强翻边效果的目的。为验证该方法的可行性，通过搭建管件翻边过程的电磁-结构全耦合有限元仿真模型，对比引入不同集磁器后的翻边效果，同时分析了不同工况对电磁力分布、电磁力密度以及磁场和涡流的影响。得出阶梯型集磁器效果最佳，结果表明，该方法下管件翻边角度从38°增大到90°。进一步分析表明，其磁通密度径向分量和涡流密度环向分量分别增大到164%和135%，作用在管件上的电磁力分布改变，峰值时刻轴向电磁力体密度明显加强，增大到211%。该方法进一步完善了对微小铝合金管件的电磁翻边成形，对拓展电磁成形技术在铝合金管件翻边上的应用具有一定意义。Abstract: Aiming at the electromagnetic flanging process for small aluminum alloy tube fittings, the driving coil is placed on the outside of the end of the tube, and the dual-frequency discharge current method is used to generate the attractive electromagnetic force to realize flanging in the existing method. However, its flanging ability is not strong, under this background, an attractive electromagnetic force flanging method with a magnetic field shaper is proposed. On the basis of the existing method, a magnetic field shaper is introduced, which can change the magnetic field configuration, optimize the electromagnetic force distribution and increase the axial electromagnetic force, so as to achieve the purpose of enhancing the flanging effect. To verify the feasibility of this method, firstly, the electromagnetic-structural fully coupled finite element simulation model of the tube flanging process was built, and the flanging effects after introducing different magnetic field shaper were compared, and it is concluded that the stepped magnetic field shaper has the best effect. The flanging process were analyzed under the working conditions with stepped magnetic field shaper and without magnetic field shaper. The results show that the flanging angle of the tube fittings is increased from 38° to 90° compared with the case without the magnetic field shaper. Further analysis shows that the radial component of the magnetic flux density and the annular component of the eddy current density increase to 164% and 135%, respectively. The distribution of the electromagnetic force acting on the pipe fittings changes, and the density of the axial electromagnetic force increases significantly at the peak time, increasing to 211%. The method further improves the electromagnetic flanging forming of small aluminum alloy tube fittings, and it has a certain significance for expanding the application of electromagnetic forming technology in aluminum alloy tube flanging.
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图 1 吸引式电磁力管件翻边装置结构示意图
Figure 1. Structural schematic diagram of suction type electromagnetic force tube flanging device
图 2 带集磁器结构的翻边系统电流分布图
Figure 2. Current distribution diagram of flanging system with magnetic field shaper structure
图 5 小管件翻边系统二维轴对称模型图
Figure 5. 2D axisymmetric model diagram of small-size tube flanging system
图 8 管件端部电磁力矢量分布对比图
Figure 8. Comparison diagram of electromagnetic force vector distribution at the end of tube fittings
图 10 磁通密度与涡流密度变化对比图
Figure 10. Comparison of changes in magnetic flux density and eddy current density
图 11 不同初始放电电压时两种工况下翻边效果
Figure 11. Flanging effect under two working conditions at different initial discharge voltages
表 1 材料参数及其几何结构参数
Table 1. Material parameters and geometric structure parameters of the model
object parameter value AA1060 aluminum alloy tube fitting material parameters density/(kg·m−3) 2710 conductance/(S·m−1) 3.76×107 relative magnetic permeability 1 relative dielectric constant 1 Poisson's ratio 0.33 initial yield stress/MPa 98 material parameters of coil and magnetic field shaper (copper) density/(kg·m−3) 8930 conductance/(S·m−1) 5.99×107 relative magnetic permeability 1 relative dielectric constant 1 geometric dimensions of the tube fitting the height of the tube fitting/mm 40 width of the tube fitting/mm 1 inner diameter of the tube fitting/mm 10 outer diameter of the tube fitting/mm 11 geometric dimensions of the coil height of a single turn coil/mm 4 width of a single turn coil/mm 1 inner diameter of the coil/mm 26 outer diameter of the coil/mm 32 the number of turns of the coil 4×6 geometric dimensions of the magnetic field shaper height of the magnetic field shaper/mm 4 inner diameter of the magnetic field shaper/mm 11 outer diameter of the magnetic field shaper/mm 24.5 
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表 2 脉冲电源系统参数
Table 2. Pulse power system parameters
parameter slow discharge system fast discharge system symbol value symbol/unit value capacitance ${C_{\rm{S}}}$/μF 3200 ${C_{\rm{F}}}$/μF 200 initial discharge voltage ${U_{\rm{S}}}$/kV 8 ${U_{\rm{F}}}$/kV 6.75 equivalent resistance ${R_{\rm{S}}}$/Ω 0.10 ${R_{\rm{F}}}$/Ω 0.09 freewheeling diode ${R_{{\rm{DS}}}}$/Ω 0.02 $ {R_{{\rm{DF}}}} $/Ω 0.02 equivalent inductance ${L_{\rm{S}}}$/mH 0.60 ${L_{\rm{F}}}$/μH 5
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表 3 不同工况下的A点位移及管件翻边角度
Table 3. Displacement of point A and flange angle of tube fittings under different working conditions
working condition Dz/mm Dr/mm θ/(°) without magnetic field shaper 2.94 5.52 38 with flat magnetic field shaper 6.27 7.88 64 with stepped magnetic field shaper 7.60 8.20 90 with trapezoid magnetic field shaper 5.85 7.65 68
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表 4 不同初始放电电压时两种工况下的翻边角度
Table 4. Flanging angles under two working conditions at different initial discharge voltages
initial
discharge
voltage/kVflanging angle
without magnetic
field shaper/(°)flanging angle
with magnetic
field shaper/(°)5.75 25 51 6.00 30 56 6.25 34 64 6.50 36 73
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