CORNET 20th Appeal - SELF - Strategy for highly flexible production of large sheet metal parts

The project SELF (Sequential ElectroMagnetic Forming -  strategy for highly flexible production of large sheet metal parts) solves the problem associated with the use of progressive innovative technology for forming metal sheets parts using the electromagnetic field force effects. This way of forming provides contactless high speed process which gives it an advantage over traditional technology (the duration of one mould cycle is between 20 and 200 microseconds). In devices designed to form metal sheets by force effects of the electromagnetic field, a current pulse with a power of tens of kJ from the energy accumulated in the generator of the forming machine in the set of capacitors is supplied to the inductor. However, fast and energetically robust mechanical impact not only affects the moulded material, but also its own inductor, which must be mechanically durable by its structure, yet its lifetime period, is limited by its high mechanical stress. Also, the design of the inductor for forming large metal sheets is problematic in terms of mechanical stress and the availability of the necessary energy.

The aim of the SELF project is to design a new EMF moulding strategy that will solve the problems described above. The basic objective of the project is to design a pulse generator that will decompose the energy needed to form a thin-walled metal material into a sequence of lower pulse amplitudes, thereby greatly reducing the repeated mechanical stress of the inductor, which will contribute to its longer life. The possibility of controlled movement of the moulded material over the inductor allows the possibility of sequential electromagnetic field forming even for larger size metal sheets. This new EMF forming strategy will extend the application capabilities of this progressive technology of the formation of metallic sheet materials using electromagnetic fields in all industries.

The project SELF is implemented on the basis of cooperation with the Fraunhofer Institute (Fraunhofer Institute of Machine Tools and Forming Technology) and the Faculty of Electrical Engineering and Informatics at VŠB-TU Ostrava.

Key activities:

1. Definition of production tasks and strategies

Task 1.1 Definition of production tasks for basic sequential EMF research

Task 1.2 Prototype selection and design

Task 1.3 Characteristics of materials

Task 1.4 Detailed planning of experiment strategies

2. Experimental analysis of sequential EMF

Task 2.1 Research between individual processes

Task 2.2 Examination of the parameter influence of the process of forming results

Task 2.3 Analysis and implementation of measurement techniques

Task 2.4 Identification and quantification of process potentials and constraints

3. Experimental development of numerical simulation for gradual EMF

Task 3.1 Defining scales, input and validation data for numerical simulations

Task 3.2 Detailed numerical modelling of a pulse electric generator

Task 3.3 Numerical calculation of inductance of complex chokes

Task 3.4 Transition modelling and simulation of electric field layout

Task 3.5 Transition modelling and simulation of heat field distribution

Task 3.6 Connection of electromagnetic, structural mechanical and thermal modelling-simulation

Task 3.7 Model to determine the non-measurable process parameters of developmental sequencing tools

4. Developmental tool for sequential EMF

Task 4.1 Conceptual solution of shapes-defining tools (mat)

Task 4.2 Design and production of shape-defining research tools WP2

Task 4.3 Numerical simulation of different variants of the induction coil

Task 4.4 Design and production of a standardized coil for EMF

5. Concept of impulse power plant optimized for sequential EMF

Task 5.1 Definition of requirements and parameters

Task 5.2 Investigation of electrical quantities of the power circuit, storage and charging of circuits

Task 5.3 Development of concepts for realization of short cycle times

Task 5.4 Development of concepts for technology implementation

Task 5.5 Development of concepts for achieving high economic efficiency

Task 5.6 Evaluation and consolidation of concepts for measurement and automation

6. Process measurement and automation

Task 6.1 Development of magnetic field measurement technology

Task 6.2 Development of voltage measurement technology

Task 6.3 Development of automated positioning of machined material and coil

Task 6.4 Development and verification of production strategies

7. Development and prototype research

Task 7.1 Numerical simulation of prototypes for production

Task 7.2 Design and production of shape defining tools for prototype production

Task 7.3 Prototype production by a step-by-step EMF method

Task 7.4 Characterization and evaluation of components

8. Comparison of sequential EMF with other technologies

Task 8.1 Certification Exam with ISF as an alternative forming technology

Task 8.2 Technical comparison of EMF and ISF (focusing on result formats)

Task 8.3 Economic comparison of EMF, ISF and other moulding techniques

9. Dissemination and project management

Task 9.1 Development of dissemination strategy

Task 9.2 Publication of goals and results of the project

Task 9.3 Internal description of the results

Task 9.4 Project management

Task 9.5 Project management and coordination meetings