A Coupled Modelling and Simulation Approach to Electromagnetic Sheet Metal Forming

Abstract

This study presents a coupled numerical and experimental investigation of electromagnetic forming (EMF) for aluminium sheets. A custom simulation framework is developed in ABAQUS/Standard using user-defined material (UMAT) and load (DLOAD) subroutines. The magnetic pressure exerted on the workpiece is computed through a finite difference-based solution of Maxwell's equations and applied to the mechanical solver. The mechanical response of the material is modelled using a strain-rate-sensitive plasticity law calibrated for aluminium 7075-O. Experimental forming trials are performed using a custom-built EMF setup, and the results are compared with numerical predictions to validate the model. The comparison shows strong agreement in deformation profiles, confirming the predictive capability of the proposed simulation strategy. This work offers a reliable computational tool for optimising EMF processes and provides insights into material behaviour under high strain rate electromagnetic loading.