Computational Analysis of a Pulsed Power Source-Based Electromagnetic Manufacturing Process

Electromagnetic manufacturing (EMMa) methods are being developed as an auxiliary to conventional manufacturing processes as it offers many potential advantages. Numerical methods are being employed to predict the plastic deformation of the workpiece. A multiphysics coupled study of transient electromagnetic, thermal, and mechanical fields is imperative to predict the dynamic deformation of the workpiece during the manufacturing process. The challenging feature of solving a multiphysics problem is the high degree of coupling between the partial differential equations involved. This article describes a fast and efficient method for analyzing a coupled transient electromagnetic and mechanical problem during the process of EMMa process. A 3-D model has been considered for the formulation of electromagnetic and mechanical field equations. The coupling is usually done using finite elements methods (FEMs) which is computationally demanding for solving Electromagnetic fields. Use of FEM for solving an EM problem requires extra fine meshing of the workpiece in order to capture the skin effect and it also needs to mesh the surrounding air domain which is of no interest. This article describes an analytical framework for computing the electromagnetic pressure distribution on the workpiece, and the results have been compared with those obtained using FEM techniques. The mechanical problem is solved using commercial available FEM tools. The effects of deformation in the geometry of the workpiece and its velocity are considered which provide more accurate results.