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Electromagnetic forming (EMF) is an effective technology for deforming metals and alloys utilizing a magnetic field using generated Lorentz powers to the workpiece ideally made of electrically conductive material in a contactless manner. The process is perceived suitable to translate a design into a manufactured component; in this case, tube diameter enlargement, besides other types of shape modifications, is applied to meet economic, ergonomic, lightweighting, and aesthetic considerations, involved in the design for manufacturing of the push-rim tube of a wheelchair. EMF is safe and easy to operate because a single die is needed and the shaping is done at high speed (Psyk et al. in J Mater Process Technol 211:787–829, 2011 [1]). EMF process is applied on a tube and turned into a ring, for purposing as a push-rim or push-ring, configured ergonomically, which rather is a customary feature for a wheelchair and common in platform-based design context (Jose and Tollenaere in J Intell Manuf 16:371–390, 2005 [2]). The two components in this forming method are the EMF coil and core. The cylindrical shapes of the coil are considered in analyzing the variation of magnetic field and Lorentz force on the different coil and core materials like Cu–Be alloy, aluminum, stainless steel, and tin (Cu–Be, Al, SS, Sn) and are performed on Ansys Maxwell. The capability assessment of the EMF process is merited through the comparison of analytical and simulation results of the magnetic field and force, to get optimum bulging in the push-rim tube surface with the maximum amount of force generated by the coil. This work aims to enlarge the push-rim diameter fulfilling ergonomic and aesthetic considerations.

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Simulation of Magnetic Field and Force with Varying Shapes of an Electromagnetic Forming Coil for the Development of the Wheelchair Structure Using FEA

  • 会议论文

  • 发表日期：

    2026年

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  • Tushar Tiwari,
  • Mohammed Rajik Khan,
  • Pranab K. Dan

摘要

Electromagnetic forming (EMF) is an effective technology for deforming metals and alloys utilizing a magnetic field using generated Lorentz powers to the workpiece ideally made of electrically conductive material in a contactless manner. The process is perceived suitable to translate a design into a manufactured component; in this case, tube diameter enlargement, besides other types of shape modifications, is applied to meet economic, ergonomic, lightweighting, and aesthetic considerations, involved in the design for manufacturing of the push-rim tube of a wheelchair. EMF is safe and easy to operate because a single die is needed and the shaping is done at high speed (Psyk et al. in J Mater Process Technol 211:787–829, 2011 [1]). EMF process is applied on a tube and turned into a ring, for purposing as a push-rim or push-ring, configured ergonomically, which rather is a customary feature for a wheelchair and common in platform-based design context (Jose and Tollenaere in J Intell Manuf 16:371–390, 2005 [2]). The two components in this forming method are the EMF coil and core. The cylindrical shapes of the coil are considered in analyzing the variation of magnetic field and Lorentz force on the different coil and core materials like Cu–Be alloy, aluminum, stainless steel, and tin (Cu–Be, Al, SS, Sn) and are performed on Ansys Maxwell. The capability assessment of the EMF process is merited through the comparison of analytical and simulation results of the magnetic field and force, to get optimum bulging in the push-rim tube surface with the maximum amount of force generated by the coil. This work aims to enlarge the push-rim diameter fulfilling ergonomic and aesthetic considerations.