Research on single multi-wave electromagnetic forming method for aluminum alloy bellows

Metal bellows are widely used in various industrial scenarios due to their excellent properties, such as pressure resistance, high-temperature resistance, and corrosion resistance. Electromagnetic forming technology for metal bellows offers advantages of rapid forming and high forming limits. Existing studies have successfully achieved single-pass electromagnetic forming of single-wave bellows. To further enhance forming efficiency, this paper systematically investigates the feasibility of single-shot discharge molding for multi-wave metal bellows. A finite element simulation model is established to analyze the dynamic forming process, identify forming difficulties, and optimize the forming effect of single multi-wave bellows. The results show that at a discharge voltage of 9 kV, the intermediate corrugation forming depth of multi-wave bellows is only 3.60 mm, with a maximum thinning rate of 25%. This is primarily attributed to insufficient axial material fluidity in the bellows and uneven high-speed deformation. Through further optimization, the optimized forming depth at the middle bellows increases to 4.00 mm (an 11.1% improvement), and the maximum thinning rate decreases to 18.9% (a 24% reduction).