Optimization of electromagnetic forming process parameters for curved specimens based on CCD-RSM

Electromagnetic forming is an efficient, non-contact high-speed forming technology widely used in aerospace, automotive manufacturing, and other industries. This paper introduces a novel curved workpiece based on an elliptical coil, with characteristics similar to rocket propellant tanks. To optimize key parameters for the electromagnetic forming of curved workpieces, the effects of discharge voltage, coil inner diameter, and coil width on the forming results are studied. Finite element simulations using COMSOL, combined with existing AA 2219-O aluminum alloy high-speed forming experimental data, validate the model's accuracy. Sensitivity analysis of key parameters for electromagnetic forming is performed, with discharge voltage, coil inner diameter, and coil width selected as factors for the central composite design (CCD). The influence of various process parameters on the forming characteristics of curved workpieces is explored. Using a response surface optimization method with a forming diameter of 100 mm as the goal, a single-objective optimization model is built to determine the optimal parameter combination. Experimental results show that when the discharge voltage is 4403.27 V, the coil inner diameter is 67.7 mm, and the coil width is 3.39 mm, the electromagnetic forming diameter of the workpiece is closest to 100 mm.