Design and optimization of an integrated multi-layer coil for decreasing the discharge energy in electromagnetic welding
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RESEARCH PAPER
Design and optimization of an integrated multi-layer coil for decreasing the discharge energy in electromagnetic welding using numerical and experimental methods Mohsen Ayaz 1 & Mehrdad Khandaei 1 & Yaser Vahidshad 2 Received: 26 September 2019 / Accepted: 7 October 2020 # International Institute of Welding 2020
Abstract An innovative integrated I-shape multi-layer coil was designed for the electromagnetic welding (EMW) process using the finite element method (FEM) combined with response surface methodology (RSM) to minimize the required discharge energy of welding. The parameters of number of layers (n), thickness of layers (t), and distance between layers (d) have been varied to optimize the values of current peak (I), frequency ( f ), magnetic flux density (B), Lorentz force (F), and impact velocity (V), simultaneously. Investigation of parameters for the design of the coil was accomplished in Maxwell®16 and LS-Dyna®4 softwares. The output results of these softwares were optimized by response surface methodology (RSM) and desirability function (DF) in Minitab®17 software. It was observed that the discharge energy for welding the aluminum (Al) to stainless steel (SS) was decreased from 6.75 to 3 kJ. The optimized coil was verified experimentally to allow good-quality welding. Keywords Integrated multi-layer coil . Electromagnetic welding . Design and manufacturing . Optimization
1 Introduction Electromagnetic welding (EMW) is a solid-state welding process that produces a weld joint by a high impact velocity of the parts [1]. The EMW system includes a capacitor bank, coil, and workpieces. When capacitors are discharged, the highdensity current flows through the conductive coil, and the associated electromagnetic field induces a strong secondary current through the nearby metal workpiece. Since the primary current in the coil and the induced current in the workpiece generally travel in opposite directions, their interactions result in a strong repulsive force namely the Lorentz force. The Lorentz force, which is generated by repelling magnetic fields, is applied to accelerate one or both joining materials (flyer plate), resulting in high collision velocity and formation of joints [2, 3]. In the EMW process, the force application is Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process * Mehrdad Khandaei [email protected] 1
Malek-Ashtar University of Technology, Tehran, Iran
2
Space Transportation Research Institute, Tehran, Iran
contact free and no working medium is required. For a long time, the EMW process has been employed for welding tubular workpieces [4–6]. Recently, this process has been applied to flat workpieces for lap joint of similar or dissimilar metals [7–14]. The EMW process can produce flat or cylindrical welds, but its equipment restricts the stored energy in the capacitor bank which results in the welding of only high electrical conductivity and high formability materials. Although this process has been known fo
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