Manufacturing: Metal Forming

Sheetmetal Forming - Magnetic Pulse Forming

The magnetic pulse forming process which uses opposing magnetic fields to force a sheet of metal onto a mandrel or other form. First, an extremely large current discharge is directed through a coil which creates a magnetic field. Capacitor banks are used to store charge for larger discharges. In the nearby sheet of metal, an opposing magnetic field is induced which causes the metal sheet to be pushed into a form of some shape. The method generates pressures up to 50 Kpsi creating velocities up to 900 fps. The process production rate can climb to 3 parts a second.

Applications -

1. fittings for ends of tubes
2. embossing
3. forming
   

Three methods of magnetic pulse forming -

1. Swaging - An external coil forces a metal tube down onto a base shape (tubular coil).
2. Expanding - an inner tube is expanded outwards to take the shape of an outer collar (tubular coil).
3. Embossing and Blanking - A part is forced into a mold or over another part (a flat coil) - This could be used to apply thin metal sheets to plastic parts.