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Numisheet IOP Publishing
Journal of Physics: Conference Series 734 (2016) 032085 doi:10.1088/1742-6596/734/3/032085

Parametric study on numerical simulation of the

electromagnetic forming of DP780 steel workpiece with
aluminium driver sheet

Hyeonil Park1,2, Jinwoo Lee1, Se-Jong Kim1, Youngseon Lee1 and Daeyong Kim1,3,§
1
Korea Institute of Materials Science, Changwondaero 797, Changwon, Gyeongnam
642-831, Republic of Korea
2
Department of Mechanical Engineering, Pusan National University, 2 Busandaehak-
ro 63beon-gil, Busan 609-735, Republic of Korea
3
Korea University of Science and Technology, 217 Gajeongro, Daejeon 305-350,
Republic of Korea
§
E-mail: daeyong@kims.re.kr (D. Kim)

Abstract. The purpose of this study is to investigate the influences of numerical parameters on
the electromagnetic forming (EMF) simulation. The 3-dimensional coupled electromagnetic-
mechanical simulations were conducted to predict the deformation behavior of the advanced
high strength steel (AHSS) sheet receiving support in EMF with aluminum driver sheet. Dual
phase (DP) 780 steel workpiece was formed into a hemi elliptical protrusion shape with
aluminum alloy AA1050 driver sheet using a flat spiral coil actuator and open cavity die. The
deformed shape of the DP780 workpiece and the computation time with respect to element size,
N cycle number and time step of electromagnetic (EM) solver were analysed.

1. Introduction
There have been the demands to apply EMF process to the AHSS sheet for shaping a reinforcement
rib or sharp edge on preformed automotive parts [1]. However, realizing it is not easy because low
conductivity of high strength steel sheet disturbs to induce the eddy current during EMF process. One
of ways to overcome this technical hurdle is using high conductivity materials as the driver sheet [2].
Because EMF process with the drive sheet is a complex problem coupled the mechanical, thermal
phenomenon as well as the electromagnetism, the numerical simulation is essential tool for
understanding the invisible multi-physics natures and designing the optimal processes. In EMF
simulation, more iterative coupling and numerical discretization accompany inevitable increasing the
numerical errors and the calculation time. Therefore the numerical parameters should be properly
selected for guaranteeing reasonable prediction accuracy and computation cost. The purpose of this
study is to investigate the influences of numerical parameters on the EMF simulation results for the
AHSS sheet with driver sheet.

2. Numerical modeling
The workpiece and driver sheet utilized in this study are a DP780 steel sheet with a thickness of
1.4mm and an aluminum alloy AA1050 sheet with a thickness of 1.0mm, respectively. The blank size

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Numisheet IOP Publishing
Journal of Physics: Conference Series 734 (2016) 032085 doi:10.1088/1742-6596/734/3/032085

of both is 200mm x 200mm. Table 1 summarizes the mechanical and electromagnetic properties of
workpiece and driver sheet.

Table 1. The mechanical and electromagnetic properties of DP780 workpiece and AA1050 driver
sheet.
Mechanical Electromagnetic
Young’s Yield Tensile Uniform Total Electric Magnetic
modulus stress stress elongation elongation conductivity permeability
(GPa) (MPa) (MPa) (%) (%) (MS/m) (μH/m)
DP780 210 546.9 832.4 14.51 23.89 3.50 875.0
AA1050 68.9 89.3 107.7 2.15 6.01 35.6 1.26

The EMF of DP780 workpiece with AA1050 driver sheet was performed using the flat spiral coil
actuator with an open cavity die to form an aimed hemi elliptical protrusion shape analogous to the
reinforcement rib as shown in Figure 1. The flat spiral coil with a cross sectional area of 30mm x 3mm
was wound with 15 turns. The gap distance between the windings is 2.5mm. The open cavity having
approximately 40mm x 100mm was machined at a mean radius of the flat spiral coil to avoid the dead
zone. A charge voltage was chosen to be 7.3kV. Refer to the reference [3] for more details.

(a) (b)
Figure 1. (a) Finite element meshes of the assembly model and (b) side view of the flat spiral coil and
the open cavity die (unit: mm).

Figure 1(a) shows the mesh assembly for EMF simulations. The eight-node hexahedron solid elements
for the workpiece, the driver sheet and the flat spiral coil, while the four-node quadrangular shell
elements for the rigid open cavity die and the lower holding die were utilized. An isotropic elasto-
plasticity model was adopted for workpiece and driver sheet by neglecting their anisotropy for the
sake of simplicity. The commercial software LS-Dyna was used to fully couple with electromagnetic
and mechanical systems in 3-dimensional spaces [4].
The influence of three numerical parameters on the numerical simulation was investigated: (1) the
element size of the workpiece and driver sheet, (2) N cycle number for electromagnetism computation
frequency between EM and structural solving matrices and (3) time step of electromagnetic solver.
Each parameter for the base line condition is chosen to be element size of 1.5×1.5 (mm x mm), N
cycle number of 20, and time step of 2 (μs), respectively. For parametric studies, the plane element
sizes were varied as 1 x 1, 1.5 x 1.5, 2 x 2, 2.5 x 2.5 and 3 x 3 (mm x mm), N cycle numbers as 1, 5,
10, 15, 20, 25, 50, 75 and 100, time steps as 0.1, 0.5, 1, 1.5, 2, 2.5, 3, 3.5 and 4 (μs). The deformed

2
Numisheet IOP Publishing
Journal of Physics: Conference Series 734 (2016) 032085 doi:10.1088/1742-6596/734/3/032085

shape in the BB’ cross section of the DP780 workpiece and computation time with respect to each
parameter were predicted and compared.

3. Results
3.1. Influence of element size
The forming height increases and is gradually saturated as the element size decreases as shown in
Figure 2(a). Figure 2(b) shows that the computation time rapidly increases as the element size
approaches to 1.0mm.

10 150 DP780 (1.4mm), 7.3kV

DP780 (1.4mm), 7.3kV

Computation time (hr)

8
Z coordinate (mm)

120
6

4 90

2 1.0mm x 1.0mm
1.5mm x 1.5mm 60
2.0mm x 2.0mm
0 2.5mm x 2.5mm
3.0mm x 3.0mm
-2 30
0 10 20 30 40 50 60 1.0 1.5 2.0 2.5 3.0
Y coordinate (mm) Mesh size (mm)
(a) (b)
12 500
DP780 (1.4mm), 7.3kV DP780 (1.4mm), 7.3kV
Computation time (hr)

10
Z coordinate (mm)

400
8

6 300
N-cycle 1
N-cycle 5
4 N-cycle 10 200
N-cycle 15
2 N-cycle 20
N-cycle 25 100
0 N-cycle 50
N-cycle 75
N-cycle 100
-2 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60 70 80 90 100
Y coordinate (mm) N cycle
(c) (d)
10 DP780 (1.4mm), 7.3kV 500
DP780 (1.4mm), 7.3kV
Computation time (hr)

8
Z coordinate (mm)

400
0.1s
6
0.5s 300
1.0s
4
1.5s
2.0s
200
2
2.5s
3.0s 100
0
3.5s
4.0s
-2 0
0 10 20 30 40 50 60 0 1 2 3 4
Y coordinate (mm) Time step (s)
(e) (f)
Figure 2. (a), (c) and (e) deformed shape and (b), (d) and (f) computation time with respect to
mesh size ((a) and (b)), N cycle number ((c) and (d)) and time step ((e) and (f)).

3
Numisheet IOP Publishing
Journal of Physics: Conference Series 734 (2016) 032085 doi:10.1088/1742-6596/734/3/032085

3.2. Influence of N cycle number

The forming height proportionally increases until N cycle number increases up to 50 as shown in
Figure 2(c). When N cycle number is more than 50, the unexpected increase of forming height is
observed. Figure 2(d) shows the computation time decreases as the N cycle number increases and
drastically increases when N cycle number is less than 10.

3.3. Influence of time step

The forming height increases as time step increases as shown in Figure 2(e). Figure 2(f) shows that the
computation time increases as the time step decreases and drastically increases when time step is less
than 1 μs.

4. Summary
The present study aims to evaluate the influence of the numerical parameters on prediction accuracy
and computation cost in the numerical simulation for the EMF of the DP780 workpiece with an
AA1050 driver sheet to hemi spherical protrusion shape. The deformed shape of the DP780 workpiece
and the computation time with respect to element size, N cycle number and time step of EM solver
were predicted. The forming height increases as the element size decreases, N cycle number and time
step increase. On the other hand, the computation time increases as all parameters decrease. Further
study to select proper parameter set is needed to compromise between the prediction accuracy and
computation cost.

References
[1] Eguia I, Mangas A and Iturbe R 2010 Electromagnetic Forming of Longitudinal Strengthening
Ribs in Roll Formed Automotive Profiles (Columbus, Ohio: Proceedings of the 4th
International Conference on High Speed Forming) pp 198–207
[2] Weimar G 1963 Hochgeschwindigkeitsbearbeitung III – Umformung von Blechen und Rohren
durch magnetische Kräfte Werkstatt und Betr. 96 893–9
[3] Park H, Kim D, Lee J, Kim S-J, Lee Y and Moon Y H 2016 Effect of an aluminum driver sheet
on the electromagnetic forming of DP780 steel sheet J. Mater. Process. Technol. 235 158–70
[4] Eplattenier P L, Cook G, Ashcraft C, Burger M, Imbert J and Worswick M 2008 Introduction
of an Electromagnetism Module in LS-DYNA for Coupled Mechanical-Thermal-
Electromagnetic Simulations (Dortmund: Proceedings of the 3rd International Conference on
High Speed Forming) pp 85–96

Acknowledgments
This study was financially supported by the Fundamental Research Program of the Korea Institute of
Materials Science and R&D programs on Fusion Core Technology for Industry (No. 10040078),
funded by the Ministry of Knowledge Economy, Republic of Korea.