Experimental and numerical study of forming aluminum stepped tubes by electromagnetic forming method

Experimental and numerical study of forming aluminum stepped tubes by electromagnetic forming method | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Experimental and numerical study of forming aluminum stepped tubes by electromagnetic forming method Javad Esmaeili, Aliakbar Asgharpour, Mohammad Bakhshi-Jooybari, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6437718/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 21 Jul, 2025 Read the published version in Discover Materials → Version 1 posted 11 You are reading this latest preprint version Abstract Challenges such as limited formability, high springback, and wrinkling in aluminum forming are addressed using electromagnetic forming (EMF), a high-speed technique that accelerates the workpiece for precise forming. This study investigates stepped tube production by EMF, experimentally and using Finite element simulation. A key focus is the detailed exploration of EMF for stepped tubes, resolving issues like uneven thinning and poor material flow. In this study, Aluminum 6063 tubes with a thickness of 0.95 mm were used. A coil was optimized in COMSOL by analyzing parameters such as the number of turns of the coil, wire spacing, and coil-to-workpiece distance to enhance quality. Additionally, implementing air venting channels in the die design eliminated dents and incomplete filling, enhancing production outcomes. Initial single-step tests at 4, 5, and 6 kV showed insufficient filling and excessive thinning, leading to the development of a multi-step approach. In addition, precise three-dimensional modeling with full coupling was improved simulation accuracy for complex geometries. Two-step and four-step methods overcame single-step limitations. Results confirmed that the two-step method at 4 kV and 6.5 kV achieved optimal outcomes, with a 30.67% expansion ratio and a 20% improvement in thickness distribution. An inverse analysis estimated the coefficient C in the Johnson-Cook model, enhancing material behavior predictions. These advancements address EMF challenges and offer opportunities for industries like automotive and aerospace. Electromagnetic forming Finite element simulation Stepped tube Thinning Die filling Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Published Journal Publication published 21 Jul, 2025 Read the published version in Discover Materials → Version 1 posted Editorial decision: Revision requested 29 May, 2025 Reviewers agreed at journal 28 May, 2025 Reviews received at journal 23 May, 2025 Reviewers agreed at journal 21 May, 2025 Reviews received at journal 11 May, 2025 Reviewers agreed at journal 10 May, 2025 Reviewers invited by journal 02 May, 2025 Editor invited by journal 30 Apr, 2025 Editor assigned by journal 28 Apr, 2025 Submission checks completed at journal 28 Apr, 2025 First submitted to journal 13 Apr, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6437718","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":451360222,"identity":"a7b6625a-c81f-4f8f-a4a4-fad666b51de7","order_by":0,"name":"Javad Esmaeili","email":"","orcid":"","institution":"Babol Noshirvani University of Technology","correspondingAuthor":false,"prefix":"","firstName":"Javad","middleName":"","lastName":"Esmaeili","suffix":""},{"id":451360223,"identity":"46a5a3ad-ad0d-417d-afe9-c1f5303c8b50","order_by":1,"name":"Aliakbar 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