GOALI: Theoretical and Experimental Investigation of Electromagnetically Formed Aluminum

本论文的目标是对铝合金电磁成形（EMF）进行系统的研究，以期：a）理解实验观察到的铝的延展性增加的机制，B）建立设计实际的此类过程所需的建模能力，以及c）教育学生在这一新的研究领域和传播知识创造的最有效的方式。该方法有一个理论和实验组成部分，并涉及工业-大学合作。新的元素所提出的工作是建模的完全耦合的热-机械和电磁问题，包括大应变，粘塑性和惯性效应。建模能力是电磁成形工艺设计不可或缺的组成部分，因为与标准板料成形操作的设计不同，（由于使用了专门的商业FEM软件包，这些软件包目前已得到高度开发），但由于缺乏适当的耦合物理模型，EMF过程的设计目前尚不存在。电磁成形技术是一种环境友好、灵活、成本效益高的板材高速成形方法，与传统技术相比具有相当大的优势。这是一项先进的技术，正在发现越来越多的汽车和航空航天应用。这项工作预计将有利于该领域提供预测能力，通过制定的完全耦合的问题和可靠的数值求解算法，支持实验验证的现实电动势过程。美铝公司和通用汽车公司（谁提供了这里报告的初步工作的种子资金）和密歇根州之间在这一研究领域的现有合作，提供了一个自然的网络，为所创造的知识的传播，而学生将在学术和工业环境中工作。

The objective of the proposed work is a systematic investigation of Electromagnetic Forming (EMF) of aluminum alloys, which is expected to: a) understand the mechanisms for the experimentally observed increased ductility in aluminum, b) establish the modeling capability required for the design of realistic such processes and c) educate students in this new research area and disseminate the knowledge created in the most efficient way.The approach has a theoretical and an experimental component and involves Industry - University collaboration. The novel element of the proposed work is the modeling of the fully coupled thermo-mechanical and electromagnetic problem with large strain, viscoplastic and inertia effects included. Modeling capability is an indispensable ingredient for the design of EMF processes, since, unlike the design of standard sheet forming operations (which are currently highly developed due to the use of specialized commercial FEM packages), the design of EMF processes is presently non-existent due, in good measure, to the lack of appropriate coupled-physics models.Broader impact and Benefits of the work: EMF technology is an environmentally friendly, flexible and cost-effective method of implementing high-velocity sheet metal forming that has considerable advantages over conventional techniques. It is an advanced technology that is finding an increasing number of automotive and aerospace applications. The work is expected to benefit the field by providing predictive capability for realistic EMF processes through the formulation of the fully coupled problem and the development of reliable numerical solution algorithms, backed by experimental validations. The existing collaboration in this research area between Alcoa and GM (who provided the seed funding for the preliminary work reported here) and Michigan, provides a natural network for the dissemination of the knowledge created, while the students will work in both academic and industrial environments.