Structural Parameter Design of Magnetic Pulse Welding Coil for Dissimilar Metal Joints: Numerical Simulation, Parameter Optimization, and Experiments
As a main component of the magnetic pulse welding (MPW) system, the working coil exerts a great influence on the electromagnetic force and its distribution, which, in turn, affects the quality of the MPW joints. This study proposes a structural parameter optimization of the MPW coil, with the object...
Saved in:
| Main Authors: | , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-01-01
|
| Series: | Machines |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2075-1702/13/1/28 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1832588049404395520 |
|---|---|
| author | Yangfan Qin Changhui Ji Hao Jiang Yuefan Jiang Junjia Cui Guangyao Li |
| author_facet | Yangfan Qin Changhui Ji Hao Jiang Yuefan Jiang Junjia Cui Guangyao Li |
| author_sort | Yangfan Qin |
| collection | DOAJ |
| description | As a main component of the magnetic pulse welding (MPW) system, the working coil exerts a great influence on the electromagnetic force and its distribution, which, in turn, affects the quality of the MPW joints. This study proposes a structural parameter optimization of the MPW coil, with the objective of achieving a higher induced current density on the flyer plate. The optimal Latin hypercube sampling technique (OLHS), Kriging approximate model, and the Non-Linear Programming by Quadratic Lagrangian (NLPQL) algorithm were employed in the optimization procedure, based on the finite element model built in LS-DYNA. The results of the sensitivity analysis indicated that all the selected parameters of the coil had a specific influence on the induced current density in the flyer plate. The optimized coil structure serves to refine the pulse current flowing path within the coil, effectively reducing the current loss within the coil. Additionally, the structure reduces the adverse effect of the current within the coil on the induced current within the flyer plate. Numerical results show the peak-induced current of the flyer plate increasing by 25.72% and the maximum Lorentz force rising by 58.10% at 25 kJ with the optimized coil structure. The experimental results show that with the same 25 kJ discharge energy, the optimized coil could increase the collision velocity from 359.92 m/s to 458.93 m/s. Moreover, 30 kJ of discharge energy should be needed to achieve the failure mode of base material failure with the original coil, while only 15 kJ should be applied to the optimized coil. These findings verify the optimization model and give some outline for coil design. |
| format | Article |
| id | doaj-art-3659c5680aeb4b689ad5e3fa941c900d |
| institution | Kabale University |
| issn | 2075-1702 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Machines |
| spelling | doaj-art-3659c5680aeb4b689ad5e3fa941c900d2025-01-24T13:39:11ZengMDPI AGMachines2075-17022025-01-011312810.3390/machines13010028Structural Parameter Design of Magnetic Pulse Welding Coil for Dissimilar Metal Joints: Numerical Simulation, Parameter Optimization, and ExperimentsYangfan Qin0Changhui Ji1Hao Jiang2Yuefan Jiang3Junjia Cui4Guangyao Li5State Key Laboratory of Advanced Design and Manufacturing Technology for Vehicle, Hunan University, Changsha 410082, ChinaState Key Laboratory of Advanced Design and Manufacturing Technology for Vehicle, Hunan University, Changsha 410082, ChinaState Key Laboratory of Advanced Design and Manufacturing Technology for Vehicle, Hunan University, Changsha 410082, ChinaState Key Laboratory of Advanced Design and Manufacturing Technology for Vehicle, Hunan University, Changsha 410082, ChinaState Key Laboratory of Advanced Design and Manufacturing Technology for Vehicle, Hunan University, Changsha 410082, ChinaShenzhen Automotive Research Institute, Beijing Institute of Technology, Shenzhen 518118, ChinaAs a main component of the magnetic pulse welding (MPW) system, the working coil exerts a great influence on the electromagnetic force and its distribution, which, in turn, affects the quality of the MPW joints. This study proposes a structural parameter optimization of the MPW coil, with the objective of achieving a higher induced current density on the flyer plate. The optimal Latin hypercube sampling technique (OLHS), Kriging approximate model, and the Non-Linear Programming by Quadratic Lagrangian (NLPQL) algorithm were employed in the optimization procedure, based on the finite element model built in LS-DYNA. The results of the sensitivity analysis indicated that all the selected parameters of the coil had a specific influence on the induced current density in the flyer plate. The optimized coil structure serves to refine the pulse current flowing path within the coil, effectively reducing the current loss within the coil. Additionally, the structure reduces the adverse effect of the current within the coil on the induced current within the flyer plate. Numerical results show the peak-induced current of the flyer plate increasing by 25.72% and the maximum Lorentz force rising by 58.10% at 25 kJ with the optimized coil structure. The experimental results show that with the same 25 kJ discharge energy, the optimized coil could increase the collision velocity from 359.92 m/s to 458.93 m/s. Moreover, 30 kJ of discharge energy should be needed to achieve the failure mode of base material failure with the original coil, while only 15 kJ should be applied to the optimized coil. These findings verify the optimization model and give some outline for coil design.https://www.mdpi.com/2075-1702/13/1/28structural parameter optimizationmagnetic pulse welding coilkriging approximate modelinductive current path optimizationcurrent loss reduction |
| spellingShingle | Yangfan Qin Changhui Ji Hao Jiang Yuefan Jiang Junjia Cui Guangyao Li Structural Parameter Design of Magnetic Pulse Welding Coil for Dissimilar Metal Joints: Numerical Simulation, Parameter Optimization, and Experiments Machines structural parameter optimization magnetic pulse welding coil kriging approximate model inductive current path optimization current loss reduction |
| title | Structural Parameter Design of Magnetic Pulse Welding Coil for Dissimilar Metal Joints: Numerical Simulation, Parameter Optimization, and Experiments |
| title_full | Structural Parameter Design of Magnetic Pulse Welding Coil for Dissimilar Metal Joints: Numerical Simulation, Parameter Optimization, and Experiments |
| title_fullStr | Structural Parameter Design of Magnetic Pulse Welding Coil for Dissimilar Metal Joints: Numerical Simulation, Parameter Optimization, and Experiments |
| title_full_unstemmed | Structural Parameter Design of Magnetic Pulse Welding Coil for Dissimilar Metal Joints: Numerical Simulation, Parameter Optimization, and Experiments |
| title_short | Structural Parameter Design of Magnetic Pulse Welding Coil for Dissimilar Metal Joints: Numerical Simulation, Parameter Optimization, and Experiments |
| title_sort | structural parameter design of magnetic pulse welding coil for dissimilar metal joints numerical simulation parameter optimization and experiments |
| topic | structural parameter optimization magnetic pulse welding coil kriging approximate model inductive current path optimization current loss reduction |
| url | https://www.mdpi.com/2075-1702/13/1/28 |
| work_keys_str_mv | AT yangfanqin structuralparameterdesignofmagneticpulseweldingcoilfordissimilarmetaljointsnumericalsimulationparameteroptimizationandexperiments AT changhuiji structuralparameterdesignofmagneticpulseweldingcoilfordissimilarmetaljointsnumericalsimulationparameteroptimizationandexperiments AT haojiang structuralparameterdesignofmagneticpulseweldingcoilfordissimilarmetaljointsnumericalsimulationparameteroptimizationandexperiments AT yuefanjiang structuralparameterdesignofmagneticpulseweldingcoilfordissimilarmetaljointsnumericalsimulationparameteroptimizationandexperiments AT junjiacui structuralparameterdesignofmagneticpulseweldingcoilfordissimilarmetaljointsnumericalsimulationparameteroptimizationandexperiments AT guangyaoli structuralparameterdesignofmagneticpulseweldingcoilfordissimilarmetaljointsnumericalsimulationparameteroptimizationandexperiments |