Finite element simulation and experimental investigation of electromagnetic hydraulic flanging for AA2024 sheet

Abstract Objectives Electromagnetic hydraulic forming (EMHF) is an innovative sheet metal forming technology. It offers high forming rates and exceptional flexibility in accommodating complex part geometries. This study investigated EMHF for pre-punched sheets. Methods By optimizing die geometry and conducting finite element simulations, the adopted scheme effectively hindered fluid leakage during the forming of perforated sheets. The process directs fluid flow towards the sheet’s pre-punched holes, thereby creating a high-pressure region that forces the sheet to conform to the entire die cavity. Results and Conclusion Comparisons between conventionally stamped and electromagnetically hydraulically formed parts revealed a significant reduction in springback in the latter due to near-zero residual elastic strain energy. At a specific discharge voltage of 11 kV, high-precision flanging of 3-mm thick sheets was achieved. This study provides a reference guide for high-speed hydraulic forming of pre-punched sheets and broadens its applications in sheet metal forming.