Magnetic-pulse car body panels flattening. Theoretical aspects and practical results
The aim of the article is to provide theoretical and experimental studying of the «induction system with an attractive screen» practical effectiveness with the excited magnetic pulse attractive forces numerical estimation. Originality. For the first time, the theoretical analysis of the electrodynam...
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| Цитувати: | Magnetic-pulse car body panels flattening. Theoretical aspects and practical results / Yu.V. Batygin, E.A. Chaplygin, O.S. Sabokar // Електротехніка і електромеханіка. — 2016. — № 4. — С. 54-57. — Бібліогр.: 12 назв. — англ. |
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Digital Library of Periodicals of National Academy of Sciences of Ukraine| _version_ | 1859938794493444096 |
|---|---|
| author | Batygin, Yu.V. Chaplygin, E.A. Sabokar, O.S. |
| author_facet | Batygin, Yu.V. Chaplygin, E.A. Sabokar, O.S. |
| citation_txt | Magnetic-pulse car body panels flattening. Theoretical aspects and practical results / Yu.V. Batygin, E.A. Chaplygin, O.S. Sabokar // Електротехніка і електромеханіка. — 2016. — № 4. — С. 54-57. — Бібліогр.: 12 назв. — англ. |
| collection | DSpace DC |
| container_title | Електротехніка і електромеханіка |
| description | The aim of the article is to provide theoretical and experimental studying of the «induction system with an attractive screen» practical effectiveness with the excited magnetic pulse attractive forces numerical estimation. Originality. For the first time, the theoretical analysis of the electrodynamics process for the «inductor system with attractive screen» at the low frequent assumption
were conducted. Methodology of the analysis applied is based on the classic electrodynamics circuits theory. All of the resulted
carried out, were obtained as the Maxwell’s differential equation solutions and its behavior was analyzed analytically. Results.
The electrodynamics process was analyzed and the principle efficiency of the «induction system with an attractive screen» as an
effective tool for magnetic pulse forming of the thin sheet metals was substantiated. The axis distributions of the attractive forces
based on the relations been obtained were illuminated graphically. The results of experimental testing of the system in the engineering operation of the external non-contact dents removing on the car body panels samples were presented. Practical value.
According to the results of the calculation analyses the fundamental workability of the «inductor system with attractive shield» as
an effective magnetic pulse sheet metal part attraction tool was proved. It was shown that the not deep metal surface damages
could be worked up by magnetic pulses technologies with a high performance in a short time.
Проведен анализ электродинамических процессов и обоснована принципиальная работоспособность «индукторной
системы с притягивающим экраном», как эффективного инструмента магнитно-импульсной рихтовки тонкостенных листовых металлов. Представлены результаты экспериментальной апробации системы в производственной
операции по внешнему бесконтактному удалению вмятин в образцах кузовных панелей автомобилей.
|
| first_indexed | 2025-12-07T16:10:57Z |
| format | Article |
| fulltext |
Техніка сильних електричних та магнітних полів. Кабельна техніка
54 ISSN 2074-272X. Електротехніка і Електромеханіка. 2016. №4
© Yu.V. Batygin, E.A. Chaplygin, O.S. Sabokar
UDC 621.311.62 doi: 10.20998/2074-272X.2016.4.07
Yu.V. Batygin, E.A. Chaplygin, O.S. Sabokar
MAGNETIC-PULSE CAR BODY PANELS FLATTENING. THEORETICAL ASPECTS
AND PRACTICAL RESULTS
The aim of the article is to provide theoretical and experimental studying of the «induction system with an attractive screen» prac-
tical effectiveness with the excited magnetic pulse attractive forces numerical estimation. Originality. For the first time, the theo-
retical analysis of the electrodynamics process for the «inductor system with attractive screen» at the low frequent assumption
were conducted. Methodology of the analysis applied is based on the classic electrodynamics circuits theory. All of the resulted
carried out, were obtained as the Maxwell’s differential equation solutions and its behavior was analyzed analytically. Results.
The electrodynamics process was analyzed and the principle efficiency of the «induction system with an attractive screen» as an
effective tool for magnetic pulse forming of the thin sheet metals was substantiated. The axis distributions of the attractive forces
based on the relations been obtained were illuminated graphically. The results of experimental testing of the system in the engi-
neering operation of the external non-contact dents removing on the car body panels samples were presented. Practical value.
According to the results of the calculation analyses the fundamental workability of the «inductor system with attractive shield» as
an effective magnetic pulse sheet metal part attraction tool was proved. It was shown that the not deep metal surface damages
could be worked up by magnetic pulses technologies with a high performance in a short time. References 12, figures 4.
Keywords: magnetic-pulse forming, inductor system, field tension, inducted current density, electromagnetic processes.
Проведен анализ электродинамических процессов и обоснована принципиальная работоспособность «индукторной
системы с притягивающим экраном», как эффективного инструмента магнитно-импульсной рихтовки тонкостен-
ных листовых металлов. Представлены результаты экспериментальной апробации системы в производственной
операции по внешнему бесконтактному удалению вмятин в образцах кузовных панелей автомобилей. Библ. 12, рис. 4.
Ключевые слова: магнитно-импульсная рихтовка, индукторная система, напряженность поля, плотность индуциро-
ванных токов, электромагнитные процессы.
Introduction and publications analysis. The ap-
plying of magnetic fields for metals engineering is
widely used [1]. Now, the contemporary technologies
allow to make production available and technically sim-
ple of the complexes for electromagnetic-pulse metals
forming (EMF). Currently EMF technology got wide-
spread throughout the world [2]. Therefore, firms like
«Boeing», «Electroimpact» and «Flextronic» use this
technology for repair namely to remove dents on the
fuselage of the aircraft [3, 4]. We should note so com-
pany like «Betag Innovation» (last «Beule Technik
AG») that has the practice-approved experience at the
area of the development of various systems for the car
body panels dents removing [5].
In the laboratory of the electromagnetic technologies
at the Kharkiv National Automobile and Highway Univer-
sity (KhNAHU) the developments in the area of the mag-
netic pulse metal forming (MPMF) takes a place.
The complex (prototype) for the external magnetic–
pulse car body panels flattening, that is consist of the
power source and the magnetic-pulse tool series for dents
removing was developed and made [6].
The power source that in special literature called like
magnetic pulse plant (MPP) is a universal devise in its
essence, withal, the tools – the magnetic field sources,
that are called inductor systems, must satisfy the carrying
out operations correctly [1, 2].
In particular, the main purpose of the magnetic–
pulse metal processing consists in the external non-
contact car body metal flattening. The detailed enough
review of these tools, repairing technologies, its appear-
ance and historical development aspects in the treaties [7]
are presented.
According to the work principle, all tools can be di-
vided in two big groups. So, the performance of the first
group is based on the sheet metal attraction, that is caused
by curtain magnetic properties under such condition as
low frequency of the action field [8, 9]. The effectiveness
of the second group tools, that have an author’s name
«inductor system with an attractive shield (ISAS)», is
determined by conductors forced attraction, that have
same directional inducted Fouke’s currents and is de-
scribed by Ampere’s low. This system consists construc-
tively of the field source– inductor that is placed between
two sheet metal conductors. One of them – is the auxiliary
attractive shield, another one is the sheet metal simple, the
current area of which is subjected to the attractive mag-
netic pulse influence [8-10].
One of the ISAS constructions is proposed by au-
thors of the patent [11]. It supposes circle inductor, con-
ductive auxiliary shield and sheet metal sample layer-to-
layer placing. Respectively, such construction of the in-
ductor system can be an effective enough tool for the con-
temporary technologies of the automobile body panel
dents removing [12].
Purpose of the article is theoretical and experimen-
tal studying of the ISAS practical effectiveness with the
excited magnetic pulse attractive forces numerical estima-
tion. The ISAS practical testing as a tool for new method
of external car bodies flattening with protective paintwork
saving. The description of the external non-contact mag-
netic pulse flattening technological route.
Theory, calculated ratio. The accepted calculated
model of the cylindrical inductor system (tool) design for
the magnetic-pulse flattening with equal thin-walled non-
magnetic sheet metals and the flat circular one-coil sole-
noid that placed above the attractive shield surface is pre-
sented in fig. 1.
According to the articles [2, 8-10] the mathematical
assumptions were accepted.
For the calculated model fig. 1 Maxwell`s equations
were composed, solution of which gives us the inducted
ISSN 2074-272X. Електротехніка і Електромеханіка. 2016. №4 55
currents time form. (Detail calculation sequence can be
reviewed in [1, 2, 7-10]). At the low frequency work
mode for the action fields, currents can be presented in
the next form.
Fig. 1. The calculated model in a cylindrical coordinate system:
1 – multicoil inductor; 2 – shield; 3 – sample; d – thickness;
R3, R4 – inner and outer radii; h – the distance from the inductor
to the shield, 2h – the distance between the shield and the metal
sample; zr eee
,, – directing vectors
The excited signal in the auxiliary shield:
0
1
)( )1(
)(),( dx
d
r
xJ
x
ee
xfJrJ
xd
h
x
m
s , (1)
where
d
dg
RR
I
J m
m
)(
234
the «conditional»
induced signal amplitude, Im and )(sin)( 0 eg –
the amplitude and the phase relation of the excited current
in the solenoid; t – phase, t – time,
.)(
1
)(
4
3
12
dyyJy
x
xf
d
R
x
d
R
x
The linear current density that is excited in the sheet
metal sample:
0
1
1
3
)( )(
)1(
)(),( dx
d
r
xJ
x
e
exfJrJ
x
d
h
x
m
p
. (2)
At the consider low frequency mode, as there have
been shown before, the attractive forces integral effi-
ciency tends to zero value [2, 10].
Under conditions of the hard auxiliary shield fixa-
tion, the sample will be subjected only to the attractive
forces influence. The attractive forces (Ampere’s forces)
dependence that presents in the terms of the inductor cur-
rent phase takes the next form [10].
)2(
),(),(),( )()(
0 h
r
rJrJrF ps
attr . (3)
The numerical estimations were made according to
the next initial data that is typical for the magnetic pulse
metal processing [1, 2]: Im = 120 kА, 15002 Hz,
005.03 R m, 05.04 R m, 001.0d m, 005.0h m.
Calculation results in the fig. 2 are presented.
a
b
Fig. 2. Spatial excited currents and attractive forces distribution:
a) the currents induced in the auxiliary shield metal – 1
and sheet metal sample – 2;
b) is the radial attractive forces distribution
On the calculated dependences in the fig. 2 it is ob-
tained that achieved attractive forces can reach up to 20
Atm. in the researched ISAS system.
The averaged surface forced impact is equal to 10
Atm. It is necessary to attend, that insignificant increase
of the current, e.g., up to 150 kA, (that is real enough
practically) gives us more than 2 times attractive forces
value increase. As the practice of magnetic-pulse metals
processing, this forced impact value is enough for effec-
tive deformation of the thin walled conductors. Ulti-
mately, the main result of the analysis of electrodynamic
processes is the conclusion about the practical effective-
ness of the proposed ISAS construction.
Experimental testing and the main results. The
ISAS principal construction that is used in experiments
and coincides with its calculated model.
Actually, based on the forced impact results, the
proposed «inductor system with attractive shield» is
56 ISSN 2074-272X. Електротехніка і Електромеханіка. 2016. №4
analogical to the well-known electromagnet, fig 3,b.
However, unlike the last, there can be realized the attrac-
tion not only for ferromagnetic, but also for metal of any
physical nature.
In the fig. 3 the magnetic pulse flattening complex
and the experimental ISAS prototype are presented. The
winding of the exciting coil is connected to the power
source – magnetic pulse plant МИУС-2, that was de-
signed and developed in the Laboratory of electromag-
netic technology KhNAHU, fig 3,a [6]. Its distinguishing
feature consists of the serial pulse work mode. It means
continuously predetermined number of charge current
pulses repetition, that eventually are transformed into the
power attraction pulses of the metal dents to the working
shield surface.
As experimental samples there were taken galva-
nized steel sheet metal samples and car body metal sam-
ples so Automobile mark like «Subaru» and «Citroen».
The samples thickness was ~ 0.0008…0.001 m. The dam-
ages, that were made in each sample were ~
0.0018…0.002 m and external diameter was 0.05 m.
а
b
Fig. 3. The external magnetic pulse flattening complex
(1 – magnetic pulse flattening tool – ISAS); 2 – the cable con-
nection; 3 – magnetic pulse plant МИУС2):
a – common complex view; b – ISAS
The technological operations was carried out under
the following terms:
stored energy and the voltage of the capacitive stor-
age ~ 2.4 kJ and 1500 V, respectively;
working frequency and the current pulse amplitude
~1500 Hz and ~12 kА, respectively;
current pulses frequency ~ 5 Hz;
power attraction pulses number, that provides
alignment of the sheet sample with a dent ~ 18…20.
In the fig. 4 there are presented the experimental
samples that illustrate examples of effective external non-
contact magnetic pulse dents removing in samples of cars
body panels of the Japanese and European production. It
is necessary to note about the safety of the protective
cover lay.
а
b
c
d
Fig. 4. The experimental samples variety of automotive steels:
«Subaru» (a – before the power impact, b – after attraction);
«Citroen» (c – before the power impact, d – after attraction)
ISSN 2074-272X. Електротехніка і Електромеханіка. 2016. №4 57
Conclusions.
1. At the low frequent assumption, the theoretical
analysis of the electrodynamical process for the «inductor
system with attractive shield» with the external one coil
circle inductor exciting were conducted.
2. The fundamental workability of the «inductor sys-
tem with attractive shield» as an effective magnetic pulse
sheet metal part attraction tool was proved.
3. The successful experimental testing of the «induc-
tor system with attractive shield» and external exciting
for the actual external non-contact dent removing opera-
tion in the European and Japan car body samples was
conducted.
4. The external magnetic pulse flattening technical rout
was disclosed and described.
5. The experiment results showed us the efficiency of
the proposed magnetic pulse flattening tool in the practi-
cal realization for the principally new flattening method
with a paintwork covering saving.
REFERENCES
1. Psyk V., Risch D., Kinsey B.L., Tekkayaa A.E., Kleiner M.
Electromagnetic forming – A review. Journal of Materials
Processing Technology, 2011, vol.211, no.5, pp.787-829. doi:
10.1016/j.jmatprotec.2010.12.012.
2. Batygin Yu.V., Lavinskiy V.I., Khimenko L.T. Impul'snyye
magnitnyye polya dlya progressivnykh tekhnologiy. Tom 1. Iz-
daniye vtoroye, pererabotannoye i dopolnennoye. [Pulsed mag-
netic fields for advanced technologies. Vol.1. 2nd edition, re-
vised and enlarged.] Kharkov, MOST-Tornado Publ., 2003.
284 p. (Rus).
3. Electromagnetic Dent Removal. Available at:
http://www.electroimpact.com/EMAGDR/overview.asp (ac-
cessed 25 May 2014).
4. Need an electromagnetic dent remover on hand. Flux-
tronic offers the best: the Portable Flux 3 dent remover.
Available at: http://www.fluxtronic.com/product.php (ac-
cessed 07 August 2014).
5. Welcome to BETAG Innovation. Available at:
http://www.betaginnovation.com (accessed 16 June 2014).
6. Laboratoriia elektromagnitnykh tekhnologii (Laboratory of
Electromagnetic Technology) Available at:
http://electromagnetic.comoj.com (accessed 10 July 2014).
7. Yuriy V. Batygin, Sergey F. Golovashchenko, Andrey V.
Gnatov. Pulsed electromagnetic attraction of sheet metals –
fundamentals and perspective applications. Journal of Materials
Processing Technology, 2013, vol.213, no.3, pp. 444-452.
doi: 10.1016/j.jmatprotec.2012.10.003.
8. Batygin Yu.V., Gnatov A.V. Magnetic-pulse attraction and
repulsion of thin-walled sheet ferromagnetics. Electrical
Technology Russia, 2012, no.8, pp. 58-65. (Rus).
9. Batygin Yuri V., Sergey F. Golovashchenko, Andrey V. Gna-
tov. Pulsed electromagnetic attraction of nonmagnetic sheet met-
als. Journal of Materials Processing Technology, 2014, vol.214,
iss.2, pp. 390-401. doi: 10.1016/j.jmatprotec.2013.09.018.
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netic-pulse attraction of nonmagnetic metals. Electrical
Technology Russia, 2014, no.2, pp. 40-52. (Rus).
11. Batygіn Yu.V., Gnatov A.V., Chaplygіn E.O., Trunova І.S.,
Gopko A.V., Sabokar O.S. Sposіb magnіtno-іmpul'snogo pritya-
gannya metalevih zagotіvok odnovitkovim krugovim іnduktorom,
roztashovanim nad dopomіzhnim ekranom [Method of the mag-
netic-pulse attraction metal workpeaces single-turn circular in-
ductor located on the auxiliary screen]. Patent UA, no.77579,
2013. (Ukr).
12. Batygin Yu.V. Experimental test of the tool for the external
EMF removing dents on a car body. International Journal of
Energy and Power Engineering, 2014, vol.3, no.4, pp. 204-208.
doi: 10.11648/j.ijepe.20140304.14.
Received 25.03.2016
Yu.V. Batygin1, Doctor of Technical Science, Professor,
E.A. Chaplygin1, Candidate of Technical Science, Associate
Professor,
O.S. Sabokar1,
1 Kharkov National Automobile and Highway University,
25, Petrovskogo Str., Kharkov, 61002, Ukraine.
phone +38 057 7073727, e-mail: batygin48@mail.ru,
chaplygin.e.a@gmail.com, o.s.sabokar@gmail.com
|
| id | nasplib_isofts_kiev_ua-123456789-147253 |
| institution | Digital Library of Periodicals of National Academy of Sciences of Ukraine |
| issn | 2074-272X |
| language | English |
| last_indexed | 2025-12-07T16:10:57Z |
| publishDate | 2016 |
| publisher | Інститут технічних проблем магнетизму НАН України |
| record_format | dspace |
| spelling | Batygin, Yu.V. Chaplygin, E.A. Sabokar, O.S. 2019-02-13T20:06:42Z 2019-02-13T20:06:42Z 2016 Magnetic-pulse car body panels flattening. Theoretical aspects and practical results / Yu.V. Batygin, E.A. Chaplygin, O.S. Sabokar // Електротехніка і електромеханіка. — 2016. — № 4. — С. 54-57. — Бібліогр.: 12 назв. — англ. 2074-272X DOI: https://doi.org/10.20998/2074-272X.2016.4.07 https://nasplib.isofts.kiev.ua/handle/123456789/147253 621.311.62 The aim of the article is to provide theoretical and experimental studying of the «induction system with an attractive screen» practical effectiveness with the excited magnetic pulse attractive forces numerical estimation. Originality. For the first time, the theoretical analysis of the electrodynamics process for the «inductor system with attractive screen» at the low frequent assumption were conducted. Methodology of the analysis applied is based on the classic electrodynamics circuits theory. All of the resulted carried out, were obtained as the Maxwell’s differential equation solutions and its behavior was analyzed analytically. Results. The electrodynamics process was analyzed and the principle efficiency of the «induction system with an attractive screen» as an effective tool for magnetic pulse forming of the thin sheet metals was substantiated. The axis distributions of the attractive forces based on the relations been obtained were illuminated graphically. The results of experimental testing of the system in the engineering operation of the external non-contact dents removing on the car body panels samples were presented. Practical value. According to the results of the calculation analyses the fundamental workability of the «inductor system with attractive shield» as an effective magnetic pulse sheet metal part attraction tool was proved. It was shown that the not deep metal surface damages could be worked up by magnetic pulses technologies with a high performance in a short time. Проведен анализ электродинамических процессов и обоснована принципиальная работоспособность «индукторной системы с притягивающим экраном», как эффективного инструмента магнитно-импульсной рихтовки тонкостенных листовых металлов. Представлены результаты экспериментальной апробации системы в производственной операции по внешнему бесконтактному удалению вмятин в образцах кузовных панелей автомобилей. en Інститут технічних проблем магнетизму НАН України Електротехніка і електромеханіка Техніка сильних електричних та магнітних полів. Кабельна техніка Magnetic-pulse car body panels flattening. Theoretical aspects and practical results Article published earlier |
| spellingShingle | Magnetic-pulse car body panels flattening. Theoretical aspects and practical results Batygin, Yu.V. Chaplygin, E.A. Sabokar, O.S. Техніка сильних електричних та магнітних полів. Кабельна техніка |
| title | Magnetic-pulse car body panels flattening. Theoretical aspects and practical results |
| title_full | Magnetic-pulse car body panels flattening. Theoretical aspects and practical results |
| title_fullStr | Magnetic-pulse car body panels flattening. Theoretical aspects and practical results |
| title_full_unstemmed | Magnetic-pulse car body panels flattening. Theoretical aspects and practical results |
| title_short | Magnetic-pulse car body panels flattening. Theoretical aspects and practical results |
| title_sort | magnetic-pulse car body panels flattening. theoretical aspects and practical results |
| topic | Техніка сильних електричних та магнітних полів. Кабельна техніка |
| topic_facet | Техніка сильних електричних та магнітних полів. Кабельна техніка |
| url | https://nasplib.isofts.kiev.ua/handle/123456789/147253 |
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