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Keywords = coil workpieces

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15 pages, 7269 KiB  
Article
Investigation of the Effect of Coil Current Waveform on Electromagnetic Tube Forming
by Fangxiong Deng, Xiaofei Xu, Yang Wang, Zhiyong Yu and Can Jiang
Metals 2025, 15(4), 367; https://doi.org/10.3390/met15040367 - 27 Mar 2025
Viewed by 384
Abstract
The coil current frequency and waveform have a great impact on the forming performance of the workpiece in electromagnetic forming. However, existing research is mostly limited to analyzing the influence of either frequency or waveform on the forming outcome independently, which makes it [...] Read more.
The coil current frequency and waveform have a great impact on the forming performance of the workpiece in electromagnetic forming. However, existing research is mostly limited to analyzing the influence of either frequency or waveform on the forming outcome independently, which makes it challenging to fully reveal the intrinsic relationship between current parameters and forming results. In this work, three discharge circuit structures are developed to generate different coil currents composed of various frequencies and waveforms, and their effects on deformation of AA6061 Aluminium alloy tube are systematically investigated through numerical and experimental approaches. Results show that a conventional circuit can generate an attenuated oscillating sinusoidal waveform consisting of several pulse half-waves, while a circuit composed of a thyristor switch can generate a half-wave current, and a circuit consisting of a crowbar circuit can generate a current with a slow decay rate. Further, it is found that at a high-frequency discharge, a current having a slow decay rate is favorable for forming efficiency, as well as reducing coil temperature, while at a low-frequency discharge, the current waveform has almost no effect on the forming efficiency; thus, a half-wave current is highly recommended to significantly reduce the coil temperature. The obtained results are of great significance in guiding the design of coil currents and optimizing electromagnetic forming technology. Full article
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22 pages, 12442 KiB  
Article
Pose Estimation of Coil Workpieces by Automated Overhead Cranes Using an Improved Point Pair Features Algorithm
by Yongbo Zhuang, Jianli Man, Yuchen Jiang, Qingdang Li and Mingyue Zhang
Sensors 2025, 25(5), 1462; https://doi.org/10.3390/s25051462 - 27 Feb 2025
Viewed by 746
Abstract
To facilitate the automation of crane operations for grabbing coil stacks in port storage areas, thereby streamlining the processes of warehousing, stacking, and transshipment for enhanced operational efficiency, this paper utilizes algorithms related to 3D point clouds for the pose estimation of coil [...] Read more.
To facilitate the automation of crane operations for grabbing coil stacks in port storage areas, thereby streamlining the processes of warehousing, stacking, and transshipment for enhanced operational efficiency, this paper utilizes algorithms related to 3D point clouds for the pose estimation of coil workpieces. To overcome the limitations of the traditional point pair feature (PPF) algorithm, a novel point cloud registration algorithm is introduced. This algorithm harnesses the advantages of the PPF algorithm in describing local features and integrates it with the Generalized Iterative Closest Point (GICP) algorithm to enhance the robustness and applicability of registration. Finally, comparative experiments demonstrate that the proposed algorithm delivers superior performance. The average pose estimation errors for one, two, and three coils are 1.1%, 1.1%, and 1.2% of the coil size, respectively, with total processing times of 3.6 s, 3.4 s, and 4.7 s, meeting the practical application requirements in terms of accuracy and timing. Full article
(This article belongs to the Section Physical Sensors)
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15 pages, 8528 KiB  
Article
Numerical Modeling and Optimization of a Quasi-Resonant Inverter-Based Induction Heating Process of a Magnetic Gear
by Tamás Orosz, Miklós Csizmadia and Balázs Nagy
Energies 2024, 17(16), 4130; https://doi.org/10.3390/en17164130 - 19 Aug 2024
Viewed by 1123
Abstract
Induction heating is a clear, cheap, and highly effective technology used for many industrial and commercial applications. Generally, a time-varying magnetic field produces the required heat in the workpiece with a specially designed coil. The efficiency of the heating process depends highly on [...] Read more.
Induction heating is a clear, cheap, and highly effective technology used for many industrial and commercial applications. Generally, a time-varying magnetic field produces the required heat in the workpiece with a specially designed coil. The efficiency of the heating process depends highly on the coil design and the geometrical arrangement. A detailed and accurate finite element analysis of the induction heating process usually needs to resolve a coupled thermoelastic–magnetic problem, whose parameters values depend on the solution of another field. The paper deals with a shrink-fitting process design problem: a gear should be assembled with an axe. The interesting part of this case study is given the prescribed low limits for critical stress, the temperature of the gear material, and the heat-treated wearing surfaces. A coupled finite-element-based model and a genetic algorithm-based parameter determination methodology were presented. A thermal imaging-based measurement validated the presented numerical model and parameter determination task. The results show that the proposed methodology can be used to calibrate and validate the numerical model and optimize an induction heating process. Full article
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17 pages, 6269 KiB  
Article
Investigation of Force-Controlled Polishing of Complex Curved PMMA Parts on a Machining Center
by Xiangran Meng, Yingpeng Wang, Xiaolong Yin, Haoyu Fu, Shuoxue Sun and Yuwen Sun
Machines 2024, 12(4), 259; https://doi.org/10.3390/machines12040259 - 14 Apr 2024
Cited by 2 | Viewed by 1833
Abstract
During the polishing process of complex curved PMMA parts, the polishing force is an important factor affecting the surface quality and optical performance. In this paper, a force-controlled polishing device integrated into a machining center to maintain the polishing force is investigated. In [...] Read more.
During the polishing process of complex curved PMMA parts, the polishing force is an important factor affecting the surface quality and optical performance. In this paper, a force-controlled polishing device integrated into a machining center to maintain the polishing force is investigated. In order to achieve the real-time active control of the polishing force, the linear voice coil motor and force sensors are used for motion and measurement. A compact structure was designed to couple the linear motion of the voice coil motor with the rotation for polishing. The force-controlled polishing system with a high real-time hardware architecture was developed to perform complex curved polishing path movement with precise force control. Next, the polishing force between the device and the workpiece was analyzed to obtain the mathematical model of the device. Considering the impact during the approaching phase of polishing, a fuzzy PI controller was proposed to reduce the overshoot and response time. To implement the control method, the controller model was established on Simulink and the control system was developed based on TwinCAT 3 software with real-time computing capability. Finally, a polishing experiment involving a complex curved PMMA part was conducted by a force-controlled polishing device integrated into a five-axis machining center. The results show that the device can effectively maintain the polishing force to improve surface quality and optical performance. Full article
(This article belongs to the Special Issue Machine Tools for Precision Machining: Design, Control and Prospects)
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28 pages, 17795 KiB  
Article
A Fast Method of High-Frequency Induction Cladding Copper Alloy on Inner-Wall of Cylinder Based on Simulation and Experimental Study
by Longlong He, Yafei Wang, Ruiyu Pan, Tianze Xu, Jiani Gao, Zhouzhou Zhang, Jinghui Chu, Yue Wu and Xuhui Zhang
Coatings 2024, 14(4), 458; https://doi.org/10.3390/coatings14040458 - 10 Apr 2024
Cited by 2 | Viewed by 1730
Abstract
To quickly repair the inner-surface damage to the hydraulic support cylinder caused by frequent scratches, corrosion, and wear in the process of fully mechanized coal mining, this paper proposes a method of high-frequency induction cladding (HIC) copper alloy on inner-wall of cylinder (IWC) [...] Read more.
To quickly repair the inner-surface damage to the hydraulic support cylinder caused by frequent scratches, corrosion, and wear in the process of fully mechanized coal mining, this paper proposes a method of high-frequency induction cladding (HIC) copper alloy on inner-wall of cylinder (IWC) to improve the corrosion, sealing and pressure retention performance of hydraulic cylinders combined with numerical simulation and experimental study. Firstly, a numerical temperature field model for HIC of copper alloy on the IWC is established to investigate various distribution patterns and influencing factors including frequency of induction heating, gap between coil and cladding, power supply rating, cladding thickness and side length of square section of induction coil, etc. Subsequently, an HIC test experiment is conducted to rigorously validate the numerical temperature field model and the experiment employs a meticulously collected dataset of temperature measurements, confirming the model’s accuracy and consistent alignment with anticipated changing trends. In addition, the experiment results were verified through microstructure observation, microhardness testing, friction-wear testing, and electrochemical corrosion parameters, which shows that the factors of induction heating frequency and others have obvious effects on the temperature field distribution of HIC copper alloy on the IWC. Under these working conditions (cladding thickness 1.5 mm, power supply rating 120 kW, heating frequency 120 kHz, gap between the cylindrical workpiece and the induction coil 3 mm, induction coil cross-sectional side length of 10 mm), the thermal impact on the cylinder barrel matrix is minimal, the metallurgical bonding between the cladding layer and the matrix is good, and there are no over burning and porosity defects. Full article
(This article belongs to the Section Corrosion, Wear and Erosion)
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16 pages, 13141 KiB  
Article
Numerical Study on Electromagnetic Hydraulic Forming Process to Overcome Limitations of Electromagnetic Forming Process
by Yeon-Bok Kim and Jeong Kim
Materials 2024, 17(7), 1586; https://doi.org/10.3390/ma17071586 - 30 Mar 2024
Cited by 1 | Viewed by 1173
Abstract
This paper provides a comparison between the conventional Electromagnetic Forming (EMF) technique and the novel Electromagnetic Hydraulic Forming (EMHF) approach. The EMHF involves the use of finite element analysis coupled with the EM and arbitrary Lagrangian–Eulerian techniques analyzed through LS-DYNA. In the free-bulge [...] Read more.
This paper provides a comparison between the conventional Electromagnetic Forming (EMF) technique and the novel Electromagnetic Hydraulic Forming (EMHF) approach. The EMHF involves the use of finite element analysis coupled with the EM and arbitrary Lagrangian–Eulerian techniques analyzed through LS-DYNA. In the free-bulge configuration, EMF is influenced by the forming coil, resulting in a dead zone and uneven forming. Additionally, EMF can only be used to shape materials with high electrical conductivity. In contrast, EMHF, driven by induced hydraulic pressure from the electromagnetic field-affected drive sheet, is independent of the electrical conductivity of the material and produces dome-shaped workpieces. For rectangular die shapes, EMF is prone to collision owing to the acceleration of the blank, which results in a reduced quality owing to bouncing. However, EMHF exhibits no bouncing effect and successfully achieves the target shape in most cases. The two techniques differ in the strain rate, with EMF at 4850/s, whereas EMHF operates at approximately 1250/s. Despite being slower, EMHF is still a high-speed forming technique. In conclusion, EMHF is a promising technique capable of addressing the shortcomings of conventional EMF and achieving improvements in forming processes. Full article
(This article belongs to the Special Issue Advances in Materials Processing Engineering)
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22 pages, 7383 KiB  
Article
Study on Temperature Field Uniformity of Dynamic Induction Heating for Camshaft of Marine Diesel Engine
by Xiaona Shi, Kelong Wang, Guochao Li, Chenghao Lyu, Lei Zhao, Jianzhi Chen, Li Sun and Hengheng Wu
Machines 2024, 12(4), 215; https://doi.org/10.3390/machines12040215 - 23 Mar 2024
Cited by 5 | Viewed by 2022
Abstract
This paper focuses on the study of the induction heating process of a camshaft in a marine diesel engine. A three-dimensional finite element model for dynamic induction heating is established using the finite element method of multi-physical field coupling, aiming to investigate the [...] Read more.
This paper focuses on the study of the induction heating process of a camshaft in a marine diesel engine. A three-dimensional finite element model for dynamic induction heating is established using the finite element method of multi-physical field coupling, aiming to investigate the temperature uniformity of the cam during this process. Three elements are analyzed in this study: the moving speed, the gap between the induction coil and the workpiece, and the width of the induction coil. These factors allow for an analysis of the temperature distribution in the thickness direction and contour line direction of the cam under various conditions. On this basis, an equivalent parameter about the temperature uniformity in the thickness direction of the cam is proposed to guide the selection of the camshaft induction heating process parameters. Full article
(This article belongs to the Section Advanced Manufacturing)
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16 pages, 15198 KiB  
Article
Evolutionary Algorithm to Optimize Process Parameters of Al/Steel Magnetic Pulse Welding
by Jiyeon Shim and Illsoo Kim
Appl. Sci. 2023, 13(23), 12881; https://doi.org/10.3390/app132312881 - 30 Nov 2023
Cited by 4 | Viewed by 1263
Abstract
The Magnetic Pulse Welding (MPW) process uses only electromagnetic force to create a solid-state metallurgical bond between a working coil and outer workpiece. The electromagnetic force drives the outer tube to collide with the inner rod, resulting in successful bonding. However, due to [...] Read more.
The Magnetic Pulse Welding (MPW) process uses only electromagnetic force to create a solid-state metallurgical bond between a working coil and outer workpiece. The electromagnetic force drives the outer tube to collide with the inner rod, resulting in successful bonding. However, due to the dissimilarity of the MPW joint, only a portion of the interface forms a metallurgical bond, which affects the quality of the joint. Therefore, the purpose of this study is to analyze the effects of process parameters on joint quality through experimental work using RSM. Furthermore, an optimization algorithm is utilized to optimize the process parameters used in magnetic pulse welding. A1070 aluminum and S45C carbon steel were used as the materials, while peak current, gap between working coil and outer tube, and frequency were chosen as the process parameters for MPW. The welding conditions are determined through experimental design. After welding, the maximum load and weld length are measured to analyze the effect of the process parameters, and a prediction model is developed. Specifically, to achieve a high-quality joint, the process parameters are optimized using the Imperialist Competitive Algorithm (ICA) and Genetic Algorithm (GA). The results reveal that the peak current is a significant parameter, and the developed prediction model exhibits high accuracy. Furthermore, the ICA algorithm proves very effective in determining the process parameters for achieving a high-quality Al/Steel MPW joint. Full article
(This article belongs to the Special Issue Advanced Manufacturing Processes)
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9 pages, 1742 KiB  
Proceeding Paper
Modelling Induction Heating of Aluminium Sheets for Hot Stamping
by Alexandre Gariépy and Guillaume D’Amours
Eng. Proc. 2023, 43(1), 26; https://doi.org/10.3390/engproc2023043026 - 18 Sep 2023
Cited by 1 | Viewed by 1878
Abstract
Hot forming of aluminium sheets enables the forming of complex shapes with high-strength alloys due to increased formability at elevated temperatures. A fast, uniform and accurate heating method is required to meet the narrow solution heat treatment window from 460 to 490 °C [...] Read more.
Hot forming of aluminium sheets enables the forming of complex shapes with high-strength alloys due to increased formability at elevated temperatures. A fast, uniform and accurate heating method is required to meet the narrow solution heat treatment window from 460 to 490 °C for AA7xxx alloys before forming. Heated plates and convection furnaces are commonly used in hot forming, but require large equipment and can have medium to long cycle times. Induction heating, which uses an alternating current in a coil surrounding the workpiece, could provide shorter heating times. However, induction heating requires a part-specific coil and can exhibit significant temperature gradients over the blank. Multi-physics electromagnetic and thermal simulation can be used as a design tool to help achieve the target temperature uniformity. In this study, induction heating of an irregular aluminium blank was modelled and validated with experimental data. Methods to improve the temperature uniformity were also tested numerically. Full article
(This article belongs to the Proceedings of The 15th International Aluminium Conference)
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9 pages, 3220 KiB  
Proceeding Paper
Response of Thin Sheet Metal on the Excitation in Electromagnetic Forming
by Björn Beckschwarte, Lasse Langstädtler and Christian Schenck
Eng. Proc. 2022, 26(1), 4; https://doi.org/10.3390/engproc2022026004 - 2 Nov 2022
Cited by 1 | Viewed by 1763
Abstract
Due to their low inertia, vibrations are stimulated during electromagnetic forming of thin sheets, whereby the excitation might involve the impact on the die and the oscillation of the electromagnetic forces. Depending on the configuration of the pulsed power generator and the resulting [...] Read more.
Due to their low inertia, vibrations are stimulated during electromagnetic forming of thin sheets, whereby the excitation might involve the impact on the die and the oscillation of the electromagnetic forces. Depending on the configuration of the pulsed power generator and the resulting tool coil current, forced and free workpiece vibrations could be observed in experiments. The results indicate an influence of the vibrations on the springback behavior after thin sheet metal forming. Due to the workpiece vibration, the forming behavior changed. The results emphasize the need of designing pulsed power generators that adapt to the desired process. Full article
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14 pages, 5061 KiB  
Article
Mechanism of Magnetic Flux Leakage Detection Method Based on the Slotted Ferromagnetic Lift-Off Layer
by Jian Tang, Rongbiao Wang, Gongzhe Qiu, Yu Hu and Yihua Kang
Sensors 2022, 22(9), 3587; https://doi.org/10.3390/s22093587 - 9 May 2022
Cited by 11 | Viewed by 3565
Abstract
Magnetic flux leakage (MFL) testing is widely used in non-destructive testing of ferromagnetic components. In view of the serious attenuation of the leakage magnetic field (LMF) caused by the transmission of LMF in the lift-off layer between the measuring point and the workpiece, [...] Read more.
Magnetic flux leakage (MFL) testing is widely used in non-destructive testing of ferromagnetic components. In view of the serious attenuation of the leakage magnetic field (LMF) caused by the transmission of LMF in the lift-off layer between the measuring point and the workpiece, this paper introduces an MFL detection method based on the slotted ferromagnetic lift-off layer (SFLL). The conventional non-ferromagnetic lift-off layer is changed to a ferromagnetic lift-off layer with a rectangular slot. The magnetic sensor is fixed above the slot and scans the workpiece together with the lift-off layer. First, the detection mechanism of the new method was studied by an equivalent LMF coil model. The permeability perturbation effect and the magnetization enhancement effect were analyzed in the new method. Based on the detection mechanism, the lift-off tolerance of the new method was investigated. Then, the LMF enhancement and lift-off tolerance of the new method in the steel plate detection model were studied. Finally, experiments were conducted to compare the new method with the conventional method. The simulation and experimental results show that the slotted ferromagnetic lift-off layer enhances the amplitude of the MFL signal and is tolerant to the lift-off value. This method provides a new idea for optimizing the design of the MFL sensor and improving the sensitivity of MFL detection at a large lift-off value. Full article
(This article belongs to the Section Industrial Sensors)
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16 pages, 6968 KiB  
Article
Effect of Plate Curvature on Heat Source Distribution in Induction Line Heating for Plate Forming
by Lichun Chang, Yao Zhao, Hua Yuan, Xiaocai Hu, Zhen Yang and Hao Zhang
Appl. Sci. 2020, 10(7), 2304; https://doi.org/10.3390/app10072304 - 27 Mar 2020
Cited by 13 | Viewed by 2896
Abstract
Line heating is an essential process in the formation of ship hull plates with a complex curvature. Electromagnetic induction heating is widely used in the line heating process. In electromagnetic induction heating, the shape of the coil and the air gap between the [...] Read more.
Line heating is an essential process in the formation of ship hull plates with a complex curvature. Electromagnetic induction heating is widely used in the line heating process. In electromagnetic induction heating, the shape of the coil and the air gap between the inductor and workpiece could influence the heat source distribution. Moreover, in the line heating process, the change of curvature of the plate will cause a change of the air gap of the inductor. Magnetic thermal coupling calculation is an effective method for simulating induction heating. This paper used the finite element method to calculate the distribution of heat sources in different initial plate curvatures and coil widths. The changes in heat source distribution and its laws were investigated. The results show that when the coil width is less than 100 mm, the effect of plate curvature on heat source distribution and strain distribution is not apparent; when the coil width is greater than 100 mm, the plate curvature has a visible effect on the heat generation distribution. In the case of a curvature increasing from 0 to 1 and a coil width equal to 220 mm, the Joule heat generation in the center of the heating area is reduced by up to 21%. Full article
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13 pages, 3566 KiB  
Article
Analytical Modeling of the Temperature Using Uniform Moving Heat Source in Planar Induction Heating Process
by Feng Li, Jinqiang Ning and Steven Y. Liang
Appl. Sci. 2019, 9(7), 1445; https://doi.org/10.3390/app9071445 - 6 Apr 2019
Cited by 28 | Viewed by 5385
Abstract
The planar induction heating possesses more difficulties in industry application compared with traditional spiral induction coils in mostly heat treatment processes. Numerical approaches are adopted in the power distribution and temperature prediction during the induction heating process, which has a relatively low computational [...] Read more.
The planar induction heating possesses more difficulties in industry application compared with traditional spiral induction coils in mostly heat treatment processes. Numerical approaches are adopted in the power distribution and temperature prediction during the induction heating process, which has a relatively low computational efficiency. In this work, an analytical calculation model of the planar induction heating with magnetic flux concentrator is investigated based on the uniform moving heating source. In this model, the power density in the surface of the workpiece induced by coils is calculated and applied into the analytical model of the temperature calculation using a uniform moving heat source. Planar induction heating tests are conducted under various induction coil parameters and the corresponding temperature evolution is obtained by the infrared imaging device NEC R300W2-NNU and the thermocouples. The final surface temperature prediction is compared to the finite element simulation results and experimental data. The analytical results show a good match with the finite element simulation and the experimental results, and the errors are in reasonable range and acceptable. The analytical model can compute the temperature distribution directly and the computational time is much less than the finite element method. Therefore, the temperature prediction method in this work has the advantage of less experimental and computational complexity, which can extend the analytical modeling methodology in induction heating to a broader application. Full article
(This article belongs to the Section Mechanical Engineering)
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