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Assessment of Process Parameters in the Optimization of the Metal Sheet Electromagnetic Forming Process

In this study, a statistical methodology using design of experiments (DoE) and the response surface methodology (RSM) is employed to optimize the electromagnetic forming (EMF) process of sheet metals with a flat spiral coil according to desirable constraints by choosing optimal process parameters and predicting the electrical and mechanical responses. Regression equations were used to carry out the optimization criterion considering the conditions for the maximum workpiece height and rise time of discharge current, and the other case included the condition for the maximum peak of discharge current. These optimizations were later validated through experiments that were in agreement with the mathematical model. Regarding the maximization of workpiece height, results showed that the windings number was the most significant parameter, followed by the capacitance and energy. Finally, process design principles for the free bulging of metal sheets by the EMF process are outlined based on experimental and statistical methods. These results can contribute to spreading industrial applications of the EMF process by introducing statistical approaches for target-oriented optimization.