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<p>Electromagnetic Forming (EMF) is a high-velocity, non-contact manufacturing process increasingly used for shaping lightweight, conductive materials. This study presents a comprehensive numerical investigation into Electromagnetic Tube Compression and Expansion, focusing on applications for lightweight alloys. A strongly coupled FEM model, developed under COMSOL Multiphysics, is used to analyze two primary configurations: free compression/expansion and die-forming compression using a 2D matrix. A key aspect is the numerical investigation of a dual-tube system that enables simultaneous compression and expansion with a single inductor. The present work provides the first comprehensive parametric and material-specific numerical validation of this configuration, demonstrating its potential for enhancing process efficiency. The simulations provide detailed insights into deformation behavior and stress distribution, and systematically evaluate the influence of critical process parameters, including discharge current, air gap, and tube thickness. A comparative analysis of Aluminum, Magnesium, and Steel confirms the superior formability of aluminum alloys under EMF conditions. These findings underscore the significant potential of EMF for producing complex, high-precision tubular components in industries such as aerospace and automotive, while the developed model serves as a robust tool for optimizing process parameters and inductor designs, thereby reducing the reliance on costly physical prototyping.</p>

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A coupled finite element analysis and parametric study of tube forming by electromagnetic compression and expansion

  • 期刊论文

  • 发表日期：

    2026年6月22日

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  • Ilhem Boutana,
  • Mohamed Rachid Mekideche,
  • Oussama Cheriet,
  • Oussama Kouissem

摘要

Electromagnetic Forming (EMF) is a high-velocity, non-contact manufacturing process increasingly used for shaping lightweight, conductive materials. This study presents a comprehensive numerical investigation into Electromagnetic Tube Compression and Expansion, focusing on applications for lightweight alloys. A strongly coupled FEM model, developed under COMSOL Multiphysics, is used to analyze two primary configurations: free compression/expansion and die-forming compression using a 2D matrix. A key aspect is the numerical investigation of a dual-tube system that enables simultaneous compression and expansion with a single inductor. The present work provides the first comprehensive parametric and material-specific numerical validation of this configuration, demonstrating its potential for enhancing process efficiency. The simulations provide detailed insights into deformation behavior and stress distribution, and systematically evaluate the influence of critical process parameters, including discharge current, air gap, and tube thickness. A comparative analysis of Aluminum, Magnesium, and Steel confirms the superior formability of aluminum alloys under EMF conditions. These findings underscore the significant potential of EMF for producing complex, high-precision tubular components in industries such as aerospace and automotive, while the developed model serves as a robust tool for optimizing process parameters and inductor designs, thereby reducing the reliance on costly physical prototyping.