Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Better metal forming: magnetic pulses “bump” metal into shape

10.10.2002


Glenn S. Daehn


Graduate student Jianhui Shang holds two pans stamped from automotive grade aluminum. The pan on the right was stamped using traditional techniques. The one on the left was stamped using the same equipment, but employing Daehn’s electromagnetic bump forming technique.


A process developed at Ohio State University for shaping metal parts using magnetism has reached a new milestone -- one that may cut manufacturing costs and help preserve the environment.

The process could also expand manufacturers’ choice of available metals, and enable the use of aluminum parts in lighter, fuel-efficient automobiles.

Glenn S. Daehn, professor of materials science and engineering, and his colleagues pioneered hybrid electromagnetic metal forming in 1999, while collaborating with the “Big Three” automakers. With this process, a traditional tool and die stamps the general shape of a part out of sheet metal. Afterward, a magnetic field pushes at specific locations of the sheet metal to form fine details or complex shapes.



Now the Ohio State engineers have discovered that they can improve the process if they use the magnetic field to stretch certain portions of the metal during the stamping operation.

In tests, they were able to create an aluminum pan with a depth nearly 1.5 times greater than previously possible, and they did so without relying upon the potentially toxic industrial lubricants normally required for stamping.

Daehn described the improved process Oct. 9 in Columbus, OH, at the annual meeting of the Minerals, Metals, and Materials Society, now known as TMS.

Daehn calls the process “bump forming,” because the magnetic field bumps against the metal in many short pulses -- typically 5 to 20 times in less than one second -- while the metal moves into the die.

Normally, as a sheet of metal bends to fit inside a tool and die, some parts of the sheet stretch more than others. These are the parts that may tear if the metal stretches too much.

With Daehn’s technique, electromagnetic fields work against the parts of the sheet that would not normally stretch, causing them to bow out. With this extra amount of “give” in the metal, other portions of the sheet will be less likely to tear.

The process works well in electrically conductive metals, including aluminum. When exposed to a strong electro-magnetic field from a coil inside the punch portion of the stamping tool, a corresponding electrical current and electromagnetic field form inside the metal. The field in the coil and the field in the metal repel each other, pushing the aluminum away from the punch.

Bump forming could be very useful in mass production, Daehn said. From the auto industry to aerospace and electronics, large manufacturing operations often need to stamp as many as 10 million copies of their metal components per year.

“The process has to be reliable, and require as little human intervention as possible,” Daehn said. “In automobile production especially, manufactures need to make parts in as few steps as they possibly can. I think we can do a lot of good things for industry with this technique.”

Daehn and Ohio State postdoctoral researcher Vincent J. Vohnout developed their bump forming technique with Ishikawajima-Harima Heavy Industries Co., Ltd., one of the largest manufacturing companies in Japan.

Using automotive-grade aluminum, the engineers stamped out a shape similar to a baking pan. Because aluminum tears easily, manufacturers typically need to coat the metal with lubricant in order to stamp it, Daehn explained. The potentially hazardous liquid is then washed from the metal and disposed of, at a significant cost.

With conventional stamping equipment and lubricant, the deepest pan they could create without tearing the aluminum was 1.7 inches (4.4 centimeters). After placing electromagnetic actuators in the same equipment and using the bump forming procedure, they were able to stamp a pan 2.5 inches (6.4 centimeters) deep -- a 47 percent increase.

Most significant to Daehn is that they were able to make a deeper impression using the same stamping pressure, and without using any lubricant.

Daehn counted off several potential benefits for industry.

“We can enable the use of higher strength materials and aluminum alloys in manufacturing. We can reduce the amount of equipment associated with metal forming. Parts that used to require multiple steps could be made with one set of tooling, which would mean a big cost savings. And we think we can eliminate reliance on these nasty lubricants,” he said.

From start to finish, the bump forming process can be designed to take five seconds or less per part, which would fit in with typical manufacturing cycles.

Daehn and Vohnout patented their bump forming process, and are seeking further funding to develop it. The National Science Foundation has largely funded the work thus far.


Contact: Glenn Daehn, (614) 292-6779; Daehn.1@osu.edu
Written by Pam Frost Gorder, (614) 292-9475; Gorder.1@osu.edu

Glenn Daehn | EurekAlert!
Further information:
http://www.osu.edu/
http://www.mse.eng.ohio-state.edu/
http://www.mse.eng.ohio-state.edu/%7Edaehn/

All articles from Materials Sciences >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Biotechnology: Triggered by light, a novel way to switch on an enzyme

In living cells, enzymes drive biochemical metabolic processes enabling reactions to take place efficiently. It is this very ability which allows them to be used as catalysts in biotechnology, for example to create chemical products such as pharmaceutics. Researchers now identified an enzyme that, when illuminated with blue light, becomes catalytically active and initiates a reaction that was previously unknown in enzymatics. The study was published in "Nature Communications".

Enzymes: they are the central drivers for biochemical metabolic processes in every living cell, enabling reactions to take place efficiently. It is this very...

Im Focus: New double-contrast technique picks up small tumors on MRI

Early detection of tumors is extremely important in treating cancer. A new technique developed by researchers at the University of California, Davis offers a significant advance in using magnetic resonance imaging to pick out even very small tumors from normal tissue. The work is published May 25 in the journal Nature Nanotechnology.

researchers at the University of California, Davis offers a significant advance in using magnetic resonance imaging to pick out even very small tumors from...

Im Focus: I-call - When microimplants communicate with each other / Innovation driver digitization - "Smart Health“

Microelectronics as a key technology enables numerous innovations in the field of intelligent medical technology. The Fraunhofer Institute for Biomedical Engineering IBMT coordinates the BMBF cooperative project "I-call" realizing the first electronic system for ultrasound-based, safe and interference-resistant data transmission between implants in the human body.

When microelectronic systems are used for medical applications, they have to meet high requirements in terms of biocompatibility, reliability, energy...

Im Focus: When predictions of theoretical chemists become reality

Thomas Heine, Professor of Theoretical Chemistry at TU Dresden, together with his team, first predicted a topological 2D polymer in 2019. Only one year later, an international team led by Italian researchers was able to synthesize these materials and experimentally prove their topological properties. For the renowned journal Nature Materials, this was the occasion to invite Thomas Heine to a News and Views article, which was published this week. Under the title "Making 2D Topological Polymers a reality" Prof. Heine describes how his theory became a reality.

Ultrathin materials are extremely interesting as building blocks for next generation nano electronic devices, as it is much easier to make circuits and other...

Im Focus: Rolling into the deep

Scientists took a leukocyte as the blueprint and developed a microrobot that has the size, shape and moving capabilities of a white blood cell. Simulating a blood vessel in a laboratory setting, they succeeded in magnetically navigating the ball-shaped microroller through this dynamic and dense environment. The drug-delivery vehicle withstood the simulated blood flow, pushing the developments in targeted drug delivery a step further: inside the body, there is no better access route to all tissues and organs than the circulatory system. A robot that could actually travel through this finely woven web would revolutionize the minimally-invasive treatment of illnesses.

A team of scientists from the Max Planck Institute for Intelligent Systems (MPI-IS) in Stuttgart invented a tiny microrobot that resembles a white blood cell...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

Dresden Nexus Conference 2020: Same Time, Virtual Format, Registration Opened

19.05.2020 | Event News

Aachen Machine Tool Colloquium AWK'21 will take place on June 10 and 11, 2021

07.04.2020 | Event News

International Coral Reef Symposium in Bremen Postponed by a Year

06.04.2020 | Event News

 
Latest News

Black nitrogen: Bayreuth researchers discover new high-pressure material and solve a puzzle of the periodic table

29.05.2020 | Materials Sciences

Argonne researchers create active material out of microscopic spinning particles

29.05.2020 | Materials Sciences

Smart windows that self-illuminate on rainy days

29.05.2020 | Power and Electrical Engineering

VideoLinks
Science & Research
Overview of more VideoLinks >>>