Abstract: There is disclosed herein an apparatus for electromagnetic forming of a workpiece with enhancements that increase the durability and overall efficiency of the solenoid coil. The apparatus includes reinforcement members dispersed through the solenoid coil and a cooling system. The apparatus also includes a shaper that varies in girth effectively acting as a force concentrator. The electromagnetic forming device is also capable of incrementally heat treating the workpiece and reducing residual stresses in the workpiece. The invention further discloses a more efficient way of manufacturing the solenoid coil.

Abstract: A method is provided for forming a sheet metal blank or tubular blank in a metal forming tool, such as a sheet metal press or a media forming tool. The sheet metal press has an upper die and a lower die that are moved by a press to form the metal blank. The forming tool has a plurality of electrodes that are connected in an electrical circuit to a source of direct current. The electrodes provide pulses of the electric current to at least a portion of the blank. The method comprises loading the blank into the forming tool and closing the upper die and the lower die. The electrical circuit is completed between multiple electrodes through one or more portions of the blank. Electrical current is pulsed intermittently through the blank in a plurality of pulses.

Abstract: A method is provided for forming a sheet metal blank or tubular blank in a metal forming tool, such as a sheet metal press or a media forming tool. The sheet metal press has an upper die and a lower die that are moved by a press to form the metal blank. The forming tool has a plurality of electrodes that are connected in an electrical circuit to a source of direct current. The electrodes provide pulses of the electric current to at least a portion of the blank. The method comprises loading the blank into the forming tool and closing the upper die and the lower die. The electrical circuit is completed between multiple electrodes through one or more portions of the blank. Electrical current is pulsed intermittently through the blank in a plurality of pulses.

Abstract: A method is provided for forming a panel from a metal alloy sheet having known stress-strain forming properties including a forming strain limit that is exceeded when a single forming operation is used to form the panel. The method comprises determining a stress relieving treatment and an incremental forming treatment for forming the panel. The total incremental forming strain comprises a first strain increment. The stress relieving treatment results in the total incremental forming strain remaining within the forming strain limit. A first preform shape is determined in which the geometry of the shape does not exceed the first strain increment. The sheet is formed into the first preform shape. The first preform shape is then stress relieved. The first preform shape is then formed into a panel shape having a geometry that is within the total incremental forming strain.

Abstract: There is disclosed herein an apparatus for electromagnetic forming of a workpiece with enhancements that increase the durability and overall efficiency of the solenoid coil. The apparatus includes reinforcement members dispersed through the solenoid coil and a cooling system. The apparatus also includes a a shaper that varies in girth effectively acting as a force concentrator. The electromagnetic forming device is also capable of incrementally heat treating the workpiece and reducing residual stresses in the workpiece. The invention further discloses a more efficient way of manufacturing the solenoid coil.