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Impact analysis in the ElectroMagnetic Welding (EMW) process with LS-DYNA

: Mani, Karthik Kumar
: Scheffler, Christian; Schwarz, Alexander; Bluhm, Joachim

Duisburg-Essen, 2020, VIII, 68 pp.
Duisburg-Essen, Univ., Master Thesis, 2020
Master Thesis
Fraunhofer IWU ()
Elektromagnetisches Schweißen; EMW; EPW; Hochgeschwindigkeit; Simulation; wave formation; LS-Dyna; electromagnetic welding; finite element method; smoothed particle hydrodynamics

The motivation of the master thesis is to investigate the effects of electromagneticpulse impact welding process. In electromagnetic impact welding, the current produces electromagnetic field which induces applied pressure on the plate. The applied pressure on the Flyer plate which makes to impact over the base plate with higher impact velocity. Due to high impact there will be high temperature between the two plates. This result helps to make welding between the plates. In the welding zone, there will be a formation of wavy surface due to the process parameter of the welding. This wave formation will be studied to investigated the possible influencing factors in the welding zone. The formation of wavy surface may happen due to impact velocity and material properties. In order to visualize the wave formation in the welding zone, the material model is analysed using LS-DYNA software. For this analysis, we use the materials which is already experimented in electromagnetic welding process. Based on experimental work, suitable material models are created and processed with Finite Element Method (FEM)and Smoothed Particle Hydrodynamics (SPH). Initially, the material model is performed with FEM model and then it is implemented with SPH method to determine the required results. The FEM numerical method is difficult to handle the large deformation and the computational time is high in the SPH method. In order to overcome this problem, hybrid model is implemented with combination of both FEM and SPH method. The simulation results achieved from the LS-DYNA software, are interpreted to understand the formation of wavy surface in the welding zone. The analyzed results are compare with pre-existing possible mechanism for wave morphology. From the analysed results, the influencing parameters such as initial impact velocity, initial impact angle and strain rate are studied and evaluated.