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Simulation of impact analysis of EPW process

: Rajamanickam, Felix Udhayaraj
: Scheffler, Christian

Duisburg-Essen, 2017, 109 pp.
Duisburg-Essen, Univ., Master Thesis, 2017
Master Thesis
Fraunhofer IWU ()

The Motivation of the master thesis is to investigation the effects of electromagnetic pulse impact welding process on a microscopic level. In electromagnetic impact welding, electromagnetic pulse is applied on the flyer plate or top plate and it impacts with the base plate with higher impact velocity. Due to the high impact there is energy transfer between the plates; the plate attains maximum temperature by high pressure and velocity from the impact. This results in formation of welding zone between the plates. In the welding zone, due to the process parameter of the welding there is formation of wavy surface and it is investigated in this thesis.
The flat and wavy surface in the welding zone is formed with respect to the impact and the material properties. Both material and process parameters will influence in the formation various stress behavior in the plates and this stress behaviors causes the local deformation. The formation of local deformations is captured in this thesis with different simulation methods. With reference to the existing research papers this problem statement is simulated in Finite Element Method (FEM) and Smooth Particle Hydrodynamics (SPH) simulations to investigate various process parameters.
The dynamic simulation can be performed in the Finite Element methods, but the microscopic level crash, impact and other similar application simulation results are more accurate in Smooth particle Hydrodynamics (SPH). The software LS-Dyna is used in this thesis to solve the problem, because the simulation gives better converging on large local deformation. These methods overcome problems with heavy mesh distortions and turned out to be advantageous for this kind of problems. It is di cult to attain the accurate results and the effect of large deformation problem in FEM. whereas the computation time is high in SPH model, to overcome the both the difficulties initial setup of the experiment is performed in FEM model and later it is implemented in SPH to obtain accurate simulation which is validated with experimental results which is obtained earlier.