Numerical simulation of the electromagnetic hot forming process of 7075-T6 aluminum alloy

To solve the problem that 7075 aluminum alloy tends to fracture during conventional forming processes, a novel forming method (electromagnetic hot forming) is introduced and investigated in this paper. The optimum mesh number (in the thickness direction) is obtained for loose-coupling method and sequential-coupling method. Then, both the loose-coupling method and the sequential-coupling method are compared with the hot forming process, and the dynamic sheet-deformation process is analyzed. With increasing temperature, the sheet forming height decreases before it increases. The simulation results, which are calculated using the sequential-coupling method, are consistent with the experimental results for four different temperatures. However, regardless of the forming temperature, either the sheet profile or the maximum forming height of the loose-coupling method differs significantly from the experimental results.

Automated summary

This paper introduces a novel forming method, electromagnetic hot forming, to solve the problem of fracture during conventional forming processes of 7075 aluminum alloy. The effectiveness of this method is studied by comparing different methods and analyzing the sheet deformation process. Consistent conclusions are obtained through the comparison of experimental and simulation results.