Magnetic pulse forming of AZ31 magnesium alloy shell by uniform pressure coil at room temperature

The magnetic pulse forming process of AZ31 magnesium alloy shell using uniform pressure coil at room temperature was investigated. ANSYS FEA software was used to analyze the distribution of magnetic flux density of the uniform pressure coil and magnetic pressure for loading on the AZ31 sheet. The characteristic of forming process of AZ31 shell was revealed, and magnetic pulse forming process of AZ31 shell and effect of Al alloy sheet with different thickness were presented by experiments. Due to impact between sheet and die, the rebound profiles on the bottom of deformed sheets were observed. In order to remove the rebound profile, AA5052 sheets were employed to drive the deformed AZ31 sheets. The section contour of R = 30 mm (R means bottom radius of die) shell deformed by 0.5-mm thickness of driver sheet driving once and R = 15 mm shell deformed by 1-mm thickness of driver sheet driving twice are good agreement with die, not only width direction (AB direction) but also length direction (CD direction). However, there was a big obstacle to deform the AZ31 shell with R = 2 mm, because the die had small bottom radius and sidewall section. Variation of effective strain and velocity with width direction and length direction during magnetic pulse forming without driver sheet and with Al driver sheet were analyzed by simulation.