Electromagnetic forming and perforations (EMFP) are complex and innovative high strain rate processes that involve electromagnetic-mechanical interactions for simultaneous metal forming and perforations. Instead of spending costly resources on repetitive experimental work, a properly designed numerical model can be effectively used for detailed analysis and characterization of the complex process. A coupled finite element (FE) model is considered for analyzing the multi-physics of the EMFP because of its robustness and improved accuracy. In this work, a detailed understanding of the process has been achieved by numerically simulating forming and perforations of Al6061-T6 tube for 12 holes and 36 holes with two different punches, i.e., pointed and concave punches using Ls-Dyna software. In order to shed light on EMFP physics, a comparison between experimental data and the formulated numerical simulation has been carried out to compare the average hole diameter and the number of perforated holes, for different types of punches and a range of discharge energies. The simulated results show acceptable agreement with experimental studies, with maximum deviations being less than or equal to 6%, which clearly illustrates the efficacy and capability of the developed coupled Multi-physics FE model.

翻译：电磁成形与穿孔技术（EMFP）是一种复杂且创新的高应变率工艺，涉及电磁-机械相互作用以实现金属成形与穿孔的同步进行。为避免在重复性实验研究中耗费高昂资源，合理设计的数值模型可有效用于该复杂过程的详细分析与特性描述。本文基于耦合有限元（FE）模型分析EMFP的多物理场特性，因其具有鲁棒性强和精度高的优势。通过使用Ls-Dyna软件对Al6061-T6铝管分别采用尖头冲头与凹面冲头进行12孔与36孔的成形与穿孔数值模拟，深入阐明了该工艺的机理。为揭示EMFP物理机制，将实验数据与数值模拟结果进行对比，针对不同冲头类型和放电能量范围，比较了平均孔径与穿孔数量。模拟结果与实验研究吻合良好，最大偏差不超过6%，充分证明了所开发耦合多物理场有限元模型的有效性与可靠性。