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<p>The application of lightweight tubes such as aluminum and magnesium alloys is vital for weight reduction in aerospace, automotive, and energy industries. However, traditional quasi-static forming processes often cause poor fit, tearing, and surface damage. Electromagnetic tube bulging, a high-speed forming method using pulsed Lorentz force, offers flexible loading but suffers from non-uniform force distribution—stronger in the middle—leading to central ruptures. This study proposes a novel electromagnetic bulging method based on an electromagnetic shielding ring structure. Compared with the conventional single-coil electromagnetic forming method, this method introduces an electromagnetic shielding ring structure composed of a copper ring and a titanium alloy ring to regulate the distribution of the forming force field during the tube bulging process. Simulations and experiments show that the ring weakens the central magnetic field, redistributing the Lorentz force and improving deformation uniformity. At a discharge voltage of 7.5&#xa0;kV, adding an electromagnetic shielding ring structure can improve the deformation uniformity of AA6061-O aluminum alloy tubes with an outer diameter of 75&#xa0;mm and a thickness of 2&#xa0;mm by about 2.5 times. Meanwhile, the forming height and uniformity of the tubes increased with the increase of the height ratio of the electromagnetic shielding ring to the discharge coil. This research work provides a new method for the effective regulation of Lorentz force distribution in the electromagnetic bulging process of tube bulging, which is an important inspiration for broadening the electromagnetic forming applications.</p>

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Controllable bulging morphology in electromagnetic tube forming via a composite shielding ring with tailored Lorentz force distribution

  • 期刊论文

  • 发表日期：

    2026年2月19日

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  • Fei Feng,
  • Jichen Han,
  • Linfeng Du,
  • Mengxian Li,
  • Zhan Tuo,
  • Xiaoxiang Li

摘要

The application of lightweight tubes such as aluminum and magnesium alloys is vital for weight reduction in aerospace, automotive, and energy industries. However, traditional quasi-static forming processes often cause poor fit, tearing, and surface damage. Electromagnetic tube bulging, a high-speed forming method using pulsed Lorentz force, offers flexible loading but suffers from non-uniform force distribution—stronger in the middle—leading to central ruptures. This study proposes a novel electromagnetic bulging method based on an electromagnetic shielding ring structure. Compared with the conventional single-coil electromagnetic forming method, this method introduces an electromagnetic shielding ring structure composed of a copper ring and a titanium alloy ring to regulate the distribution of the forming force field during the tube bulging process. Simulations and experiments show that the ring weakens the central magnetic field, redistributing the Lorentz force and improving deformation uniformity. At a discharge voltage of 7.5 kV, adding an electromagnetic shielding ring structure can improve the deformation uniformity of AA6061-O aluminum alloy tubes with an outer diameter of 75 mm and a thickness of 2 mm by about 2.5 times. Meanwhile, the forming height and uniformity of the tubes increased with the increase of the height ratio of the electromagnetic shielding ring to the discharge coil. This research work provides a new method for the effective regulation of Lorentz force distribution in the electromagnetic bulging process of tube bulging, which is an important inspiration for broadening the electromagnetic forming applications.