Numerical Investigation of Thickness-Driven Formability in High-Speed Electromagnetic Sheet Forming

Electromagnetic Forming (EMF) is an advanced high-speed manufacturing process that leverages magnetic forces to shape metallic workpieces without direct contact. This paper presents a comprehensive numerical investigation into the influence of aluminum sheet thickness on formability during electromagnetic bulging. A fully coupled finite element model is established to simulate electromagnetic fields and the dynamic deformation of the workpiece complex interaction. Aluminum disks of varying thicknesses are analyzed under identical forming conditions to evaluate the evolution of eddy currents, magnetic flux densities, and deformation profiles. The results reveal that thinner sheets exhibit higher eddy current densities, greater magnetic forces, and significantly larger central deflections, thus demonstrating superior formability. These findings are consistent with experimental observations, validating the accuracy of the model.