Flanging and Hemming of Auto Body Panels using the Electro Magnetic Forming technology
Electro Magnetic Forming (EMF) technology has a great number of potential applications for the automotive industry. LABEIN-Tecnalia has worked with this technology for six years and has a good understanding of the automotive industry’s needs and challenges. LABEIN-Tecnalia is currently developing new applications with EMF technology. Taking into account the advantages and limitations of EMF, bending and hemming processes present good geometric conditions for the use of this technology. The study presented is based largely on hemming circular configurations which are simplifications of those commonly used on hemmed automotive parts. The parameters of this new EMF bending and hemming processes have been studied, as well as their influence on the final quality of the parts obtained. Conclusions obtained from the basic geometries were tested on a more complicated geometry in order to apply the knowledge acquired. Parallel to the experimental work, fully coupled electromechanical software by LS-DYNA has been used to simulate and extend the present hemming results.
Magnetic pulse welding: An efficient and environmentally friendly multi-material joining technique
Magnetic pulse welding, a high speed joining process using electromagnetic forces, because of clean and multi-material operation has a wide range of possibilities for further development and application. Unlike conventional joining processes, the weld interface does not melt keeping the material properties intact without generation of hazardous emissions in form of heat, fume, and spatters. This paper presents a comprehensive review that considers almost all the major aspects of the subject. The paper first gives a general understanding of the process starting from its origin to its modern day status and states the widespread industrial applicability of the process. A detailed discussion of the current state of art in magnetic pulse welding is then presented. The operating principle is then described along with detailed insight into the various mechanisms responsible for a sound welded joint. The parameters controlling the process along with their effect on the weld are discussed followed by the various advantages and limitations of the process. Future trends in joining using magnetic pulse welding based upon current research developments are finally highlighted.
Neutron Residual Stress Measurements on Rail Sections for Different Production Conditions
Rail sectioning with subsequent neutron diffraction experiments has been used to assess residual stresses in the rails. In this study we present the results of neutron stress measurements performed at the NIST Center for Neutron Research (NCNR) on rail sections from rails that were produced under various conditions. Specifically, these are air-cooled, air-cooled and roller-straightened, head-hardened and head-hardened and roller-straightened. More significantly, a head-hardened and roller-straightened rail was also studied after service to elucidate evolution of the service-induced residual stresses. In the latter case both a transverse-cut slice and the central region of a 0.53 m long piece were studied. Measurements on this piece are the first in which triaxial stresses have been determined for an intact rail. Neutron strain measurements with 3×3×3 mm3 spatial resolution were successfully employed for transversally cut slices to verify the difference in the stress state depending on the production process. Although examination of slices allows determination of only two-dimensional stresses in the plane of the slice, additional measurements on obliquely-cut slices, which were also carried out, and utilization of FEM gives the possibility of reconstructing the full triaxial stress distribution. Together, these approaches provide a better understanding of rail fabrication and the possibility of improving the durability and safety of rails in the future.Copyright © 2004 by ASME