Comparison of Coupled and Non-Coupled Finite Element Models for Joining of Cu-SS Tubes by Electromagnetic Forming

Abstract

Joining by electromagnetic forming is a high-speed joining technique mostly used for joining axisymmetric components without any metallic bond formation. It possesses huge potential for industrial applications. Finite elements models are proven very helpful in analyzing the various aspects of electromagnetic forming. Non-coupled simulation is observed to be more user-friendly and less time-consuming but less accurate at the same time. However, coupled approached is observed to more accurate but at the same time being more time consuming and bring more complexity. Therefore, this paper discusses a comparative analysis between coupled and non-coupled approach for solving electromagnetic-mechanical problems during joining of Cu-SS tubes by electromagnetic forming. The coupled model is developed using LS-Dyna TM EM module, which uses the finite element method combined with the boundary element method to solve electromagnetic and mechanical process. While the coupled model is developed, using ANSYS Maxwell package to solve electromagnetic problem coupled with ANSYS explicit dynamics module to solve the mechanical problem. The magnetic field, velocity, effective plastic strain, deformation and thinning of outer tube is compared.