Advancing sheet metal stamping: the power of axial-radial Lorentz force synergistic forming

Traditional cold stamping of aluminum alloy sheet metal typically experiences low formability due to its tendency to tear easily. To address this challenge, a new stamping process incorporating axial-radial bidirectional Lorentz force loading is proposed. A dual-coil, dual-power experimental system and a simulation platform are developed for analysis. Experimental and numerical results show that pulsed radial force effectively enhances flange material flow, significantly improving the formability of aluminum alloy sheet metal. Furthermore, the proposed approach improves the deep drawing process of cylindrical cups and square boxes. Compared to the stamping process using only axial Lorentz force, the maximum forming height increases by 62.16% and 104.92%, respectively, in these two processes. This axial-radial Lorentz force synergistic stamping process provides a crucial pathway for achieving high-performance sheet metal stamping and paves the way for its extensive application in lightweight alloys.