基于短时脉冲电流的电磁变压边高能效成形方法及其能量特性研究

doi:10.3901/JME.2025.23.203

机械工程学报 ›› 2025, Vol. 61 ›› Issue (23): 203-216.doi: 10.3901/JME.2025.23.203

• 数字化设计与制造 • 上一篇

扫码分享

基于短时脉冲电流的电磁变压边高能效成形方法及其能量特性研究

李磊^1,2,3, 胡国增^1,2,3, 宣登仕¹, 黄海鸿^1,2,3

1. 合肥工业大学机械工程学院合肥 230009;
2. 合肥工业大学机电产品低碳循环利用技术与装备安徽省重点实验室合肥 230009;
3. 合肥工业大学机械工业绿色设计与制造重点实验室合肥 230009

收稿日期:2024-12-20 修回日期:2025-05-18 发布日期:2026-01-22
作者简介:李磊,1990 年出生,副教授、博士研究生导师。主要研究方向为绿色化智能高效成形工艺与装备。E-mail:lei_li@hfut.edu.cn
胡国增,2000 年出生,硕士研究生。主要研究方向为电磁控制。E-mail:1924149671@qq.com
黄海鸿(通信作者),1980 年出生,教授、博士研究生导师。主要研究方向为绿色成形制造、智能再制造等。E-mail:huanghaihong@hfut.edu.cn
基金资助:
国家自然科学基金青年基金(52005146);国家自然科学基金面上(52375492);国家自然科学基金联合基金重点(U20A20295)资助项目

Short-time Pulse Based Electromagnetic Variable Blank Holding for High Efficiency Forming and Analysis of Energy Characteristics

LI Lei^1,2,3, HU Guozeng^1,2,3, XUAN Dengshi¹, HUANG Haihong^1,2,3

1. School of Mechanical Engineering, Hefei University of Technology, Hefei 230009;
2. Anhui Provincial Key Laboratory of Low Carbon Recycling Technology and Equipment for Mechanical and Electrical Products, Hefei University of Technology, Hefei 230009;
3. Key Laboratory of Green Design and Manufacturing for Machinery Industry, Hefei University of Technology, Hefei 230009

Received:2024-12-20 Revised:2025-05-18 Published:2026-01-22

摘要/Abstract

摘要： 电磁压边相较于传统液压垫，在压边力曲线的加载柔性和精度上具有显著优势，并且能有效降低成形装备的装机功率。然而，持续不断的电流加载使得电磁压边装置能耗高，并引发过热问题，成为连续成形中亟待解决的关键挑战。为此，提出了基于短时脉冲电流的电磁变压边高能效成形方法，设计了电永磁驱动变压边成形系统，利用磁体BH曲线中的工作点迁移规律，建立了短时脉冲电流加载电磁力、电流卸荷后维持剩磁力的电磁力加载与变压边力反馈控制技术，构建了脉冲电流作用下的电磁力变化及能量表征模型，明晰了短时脉冲电流变压边的高能效、低能耗机制。搭建了基于Simulink-Simplorer-Maxwell的电/磁/力耦合仿真模型，在相同变电磁力输出下，短时脉冲电流加载能耗仅为连续电流加载的9.87%。应用于车门原型件的电磁压边成形实验表明，短时脉冲电流的变压边力加载在保证成形质量的同时，能耗仅为连续电流的14.03%、液压机吨位需求减少14%。研究为实现复杂曲面低吨位、连续成形的装备设计提供理论和方法支撑。

关键词: 电磁压边, 短时脉冲, 高能效, 成形

Abstract: Electromagnetic blank holding force offers greater loading flexibility and accuracy compared to traditional hydraulic cushions, and it also reduces the power requirement for forming equipment. Compared to traditional hydraulic cushions, electromagnetic blank holding offers significant advantages in the flexibility and precision control of the blank holding force curve, which can effectively reduce the installed power of the forming equipment. However, the continuous loading of current results in high energy consumption and overheating problems in electromagnetic blank-holding devices, presenting a significant challenge that requires attention in continuous forming. Therefore, a high-energy efficiency forming method for electromagnetic variable blank holding based on short-time pulse current is proposed. The electrical permanent magnet-driven variable blank holding forming system is designed, and feedback control is established for electromagnetic force loading under a short-time pulse current. According to the working point migration law in the magnet BH curve, the residual magnetic force after current unloading is used for variable blankholding. A model for electromagnetic force change and energy characterization under the action of pulse current is constructed to reveal the high-energy efficiency and low-energy consumption mechanism of the variable blank holding of short-time pulse current. A simulation model of electrical/magnetic/mechanical coupling is developed using Simulink-Simplorer-Maxwell. It is observed that the energy consumption during short-time pulse current loading, with the same variable electromagnetic force output, is only 9.87% of that during continuous current loading. The electromagnetic blank holding forming experiment conducted on the prototype of car doors demonstrates that the loading of variable blank holding force using short-time pulse current ensures forming quality while consuming only 14.03% of the energy compared to continuous current loading. Additionally, it reduces the tonnage requirement of hydraulic presses by 14%, which provides theoretical and methodological support for designing equipment to achieve low-tonnage, high-precision continuous forming of complex surfaces.

Key words: electromagnetic blank holding force, short-time pulse, high efficiency, forming

中图分类号:

TH139

李磊, 胡国增, 宣登仕, 黄海鸿. 基于短时脉冲电流的电磁变压边高能效成形方法及其能量特性研究[J]. 机械工程学报, 2025, 61(23): 203-216.

LI Lei, HU Guozeng, XUAN Dengshi, HUANG Haihong. Short-time Pulse Based Electromagnetic Variable Blank Holding for High Efficiency Forming and Analysis of Energy Characteristics[J]. Journal of Mechanical Engineering, 2025, 61(23): 203-216.

参考文献

[1] OBERMEYER E,MAJLESSI S. A review of recent advances in the application of blank-holder force towards improving the forming limits of sheet metal parts[J]. Journal of Materials Processing Technology, 1998, 75(1-3):222-234.
[2] YUN J,OH S,CHOI K,et al. Finite element analysis of spring back caused by frictional force in area of flange in press bending process[J]. Journal of the Korea Society of Die & Mold Engineering,2021,15(2):63-69.
[3] CHANG L,WU C,TSAO T,et al. Motion and force control of servo die cushion system using bilateral control[J]. IFAC-PapersOnLine,2022,55(27):44-49.
[4] URMAMEN M,GÜRKAN A,MURAT D,et al. Design, fabrication and performance tests of a double-sided sheet hydroforming test system[J]. 2023,30(2):314-322.
[5] MCLAUGHLIN E,GUPTA T,FALLAHIAREZOODAR A,et al. Reducing springback in hat-shape bending with variable bhf using a servo-hydraulic cushion[J]. Stamp J. March/April,2018:16-17.
[6] KITAYAMA S,YOKOYAMA M,KAWAMOTO K,et al. Practical approach of simultaneous optimization of variable blank holder force and variable slide velocity trajectory in sheet metal forming[J]. The International Journal of Advanced Manufacturing Technology,2018, 98:2693-2703.
[7] MODI B, KUMAR D. Optimization of process parameters to enhance formability of AA 5182 alloy in deep drawing of square cups by hydroforming[J]. Journal of Mechanical Science and Technology,2019,33:5337-5346.
[8] KIM H,GU J,ZOLLER L. Control of the servo-press in stamping considering the variation of the incoming material properties[J]. IOP Conference Series:Materials Science and Engineering,2019,651(1):012062.
[9] FALLAHIAREZOODAR A,GUPTA T,GOERTEMILLER C,et al. Residual stresses and springback reduction in u-channel drawing of Al5182-O by using a servo press and a servo hydraulic cushion[J]. Production Engineering, 2019,13:219-226.
[10] XU Zhicheng,LIU Yanxiong,HUA Lin,et al. Energy analysis and optimization of main hydraulic system in 10000 kN fine blanking press with simulation and experimental methods[J]. Energy Conversion and Managemen,2019,181:143-158.
[11] QIN Siji,CHENG Xiao,ZHANG Hongsheng,et al. Analyses of thermal field and coupled magnetic-mechanical field in electro-permanent magnet blank holder technique[J]. The International Journal of Advanced Manufacturing Technology, 2020, 110:499-510.
[12] DU Limeng,LI Xian,XIA Liangyu,et al. Numerical and experimental verification of an iterative coupling method for analyzing the lorentz-force-driven sheet metal stamping process[J]. The International Journal of Advanced Manufacturing Technology,2021,115(7-8):2161-2173.
[13] FAN Zengzeng,WANG Qiang,HE Fang. Fuzzy control of electromagnetic blank holder system[C]//2020 Chinese Control And Decision Conference (CCDC). IEEE,2020:165-170.
[14] HUANG Haihong,LÜ Qingyu,LI Lei,et al. Individually segmented blank holding system driven by electromagnetics for stamping:modeling,validation,and prototype[J]. Journal of Materials Processing Technology, 2023,313:117883.
[15] HE Sicheng,SUN Yonggen,QIN Siji. A novel punching process with electronically permanent magnetic technology[J]. The International Journal of Advanced Manufacturing Technology,2024,131(12):5801-5813.
[16] 张红升,秦泗吉,曹丽琴. 基于磁力控制的径向分区压边拉深工艺研究[J]. 中国科学:技术科学,2021,51(4):388G398. ZHANG Hongsheng,QIN Siji,CAO Liqin. Deep drawing with radial segmental blank holder based on magnetic control[J]. Science China:Technological Sciences,2021, 51(4):388G398.
[17] QIN Siji,ZHANG Hongsheng,MAO Yaoben,et al. Electropermanent magnet blank holder technique in sheet metal deep drawing[J]. The International Journal of Advanced Manufacturing Technology, 2020, 106:5497-5507.
[18] ZHANG Hongsheng, QIN Siji, CAO Liqin, et al.Research on deep drawing process using radial segmental blank holder based on electro-permanent magnet technology[J]. Journal of Manufacturing Processes,2020, 59:636-648.
[19] 史锐,秦泗吉,潘自给,等. 考虑磁场区影响的电控永磁压边方法[J]. 中国机械工程,2023,34(1):102-108. SHI Rui,QIN Siji,PAN Zigui,et al. An electro-permanent magnet blank holder method considering influences of magnetic field region[J]. China Mechanical Engineering, 2023,34(1):102-108.
[20] HE Sicheng,SUN Yonggen,ZHANG Jiacheng,et al. Research on multi-stage deep drawing with electro-permanent magnet technology[J]. Journal of Manufacturing Processes,2023,108:373-383.
[21] HUANG Haihong, SANG Haojie, LI Lei, et al. High-accuracy control of variable blank holding force driven by electromagnetics based on pulse width modulation with grading voltage and mode matching[J]. Journal of Materials Processing Technology,2023,322:118210.
[22] OSKIRKO V,GONCHARENKO I,ARESTOV S. Short pulse enhanced vacuum arc evaporation[J]. Vacuum, 2022,205:111459.
[23] EBENEZER G,KHAN M,JAPPES J. Influence of short-pulsed laser and its thermal effect on micromachining of NiTi alloy[J]. Academy Proceedings in Engineering Sciences,2022,47(4):201.
[24] ULLSPERGER T, LIU Dongmei, YÜREKLI B. Ultra-short pulsed laser powder bed fusion of Al-Si alloys:Impact of pulse duration and energy in comparison to continuous wave excitation[J]. Additive Manufacturing,2021,46:102085.
[25] JIN T,LEI J,QIU S. Optimization of segmented variable holding force liquid-filled drawing process[J]. Journal of Plasticity Engineering,2010,17(04):53-57.

基于短时脉冲电流的电磁变压边高能效成形方法及其能量特性研究

Short-time Pulse Based Electromagnetic Variable Blank Holding for High Efficiency Forming and Analysis of Energy Characteristics

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	杜心伟, 魏艳红, 沈泳华, 赵文勇, 刘仁培. 电弧增材制造装备系统与应用的发展现状[J]. 机械工程学报, 2025, 61(6): 92-102.
[2]	姜自昊, 肖宏, 曾才有, 张权, 杨清福, 谢非, 马康, 王亚森, 齐铂金, 从保强. 中厚铝合金DP-VPTIG焊接深熔小孔作用机制研究[J]. 机械工程学报, 2025, 61(6): 133-140.
[3]	陈鑫, 龚颖颖, 杨立飞. 考虑各向异性和剪切行为的GTN损伤模型及其在成形极限预测中的应用[J]. 机械工程学报, 2025, 61(6): 141-150.
[4]	胡志力, 芦俊杰, 魏鹏飞, 华林. Al-Zn-Mg-Cu合金预强化高效精确热冲压变形规律与力学性能研究[J]. 机械工程学报, 2025, 61(6): 160-173.
[5]	党嘉强, 安庆龙, 李宇罡, 明伟伟, 王浩伟, 刘忠明, 陈明. 航空齿轮齿根磨削和超声滚压表面完整性分布规律研究[J]. 机械工程学报, 2025, 61(5): 343-353.
[6]	江晟达, 何霁, 郭聪, 李淑慧, 钱昌明. 数据驱动的自洽聚类分析方法及塑性成形高效跨尺度模拟[J]. 机械工程学报, 2025, 61(4): 74-85.
[7]	盈亮, 陈智刚, 戴明华, 王大恩, 胡平, 韩小强. 热塑性PA6碳纤维/铝基纤维金属层板温热胀形性能及失效行为研究[J]. 机械工程学报, 2025, 61(4): 116-126.
[8]	张坤, 白雪山, 孙进, 胡馨予, 林艳丽, 何祝斌. 各向异性屈服准则对铝合金挤压管液压成形仿真精度的影响[J]. 机械工程学报, 2025, 61(4): 167-175.
[9]	顾冬冬, 孙婧佳, 朱清杰, 汪瑞, 杨家慧, 张玉玺. 结构参数与成形角度对激光粉末床熔融内流道成形质量的影响机制[J]. 机械工程学报, 2025, 61(3): 392-402.
[10]	陈祉旭, 陈远航, 李晨星, 杨春利. 复杂叶片修复的电弧熔丝沉积姿态控制方法研究[J]. 机械工程学报, 2025, 61(22): 47-56.
[11]	卢书林, 王建峰, 占小红, 段宇航, 程立宏, 黄舒文, 赵耀邦. 预成形和热处理工序对2219铝合金旋压薄壁结构应力分布的影响[J]. 机械工程学报, 2025, 61(22): 57-68.
[12]	唐恒, 黄强, 伍春霞, 孙亚隆, 汤勇. 聚合物阵列微沟槽吸液芯结构热压成形及机理研究[J]. 机械工程学报, 2025, 61(22): 80-87.
[13]	王桐, 徐潇杰, 王万礼, 杨倩, 张挺, 杨毅. 基于激光扫描模拟的预应力喷丸变形等效计算模型研究[J]. 机械工程学报, 2025, 61(20): 143-153.
[14]	王大豪, 潘飞, 赵全光, 方进秀. 2A12铝合金板电脉冲辅助渐进成形极限研究[J]. 机械工程学报, 2025, 61(18): 151-160.
[15]	张保玉, 邓文君, 汤勇, 唐恒. 铜微针阵列结构犁挤-切削加工及其成形机理[J]. 机械工程学报, 2025, 61(17): 371-380.