Multioperational Electromagnetic Forming Machine

IPASJ International Journal of Mechanical Engineering (IIJME)
Web Site: http://www.ipasj.org/IIJME/IIJME.htm

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Volume 5, Issue 4, April 2017 ISSN 2321-6441
MULTIOPERATIONAL ELECTROMAGNETIC
FORMING MACHINE
Abhishek Rane1, Ghanshyam Pendurkar2, Tejas Phage3, Aniket natalkar4, Ganesh Pednekar5
1
Professor, SSPMs college of engineering, Kanakavli, Maharashtra, India
2
Student, SSPMs College of Engineering, Kankavli, Maharashtra, India
3
4
5
ABSTRACT
The purpose of this project is to design and fabricate the economic machine for small sized sheet metal products.
Conventionally for production of these products large machines are used which are not cost economical. Also there is a loss of
energy due to friction. The objective of this project is to reduce the energy consumption, cost and to perform the various
forming operations on a single machine. The solution is obtained with the implementation of Electromagnet. Since the
actuation is electrically assisted the operation is frictionless and accurate. The punching force is controlled by varying current
using DIMMER circuit. The power is consumed only during the punching stroke resulting into efficient operation. After
successful fabrication, the set up was tested and optical testing is done for any defects in the punched samples.
Keywords: Sheet Metal, Friction, Energy, Forming, Electromagnet, Punching, DIMMER, Optical testing
1. INTRODUCTION
Sheet metal industry is one of the vast and rapidly growing industries. The intense researches are going on to develop
more efficient and economical machines to carry out sheet metal forming operations. Conventionally, the machines
used are mechanical press, hydraulic press, pneumatic press etc. These machines are often large in construction as
compared to the product to be manufactured. Also there is a loss of energy due to friction.
To overcome the disadvantages of conventional machine we implemented new concept based on Electromagnetism.
With help of electromagnet the punch plate is made to move for punching operation. Various operations like punching,
embossing, notching, slitting, perforating, bending can be performed on thin sheets of metal sheet, card board, asbestos,
paper, foam, plastic etc. The required force for any operation can be obtained by controlling the power. We provide the
DIMER circuit for controlling the power. The capacity of machine depends upon the size and the number of coils of
an electromagnet.
2. PRINCIPLE OF ELECTROMAGNET
Faradays law of induction is a basic law of electromagnetism. It is the fundamental operating principle of
transformers, inductors, electric motors, generators and solenoids. Electromagnetism is the production of magnetic field
by current in a conductor. When current passes through coil windings, an electromagnetic field is created around the
coil [1]. An electromagnet is a type of magnet in which the magnetic field is produced by an electric current. A simple
electromagnet consisting of a coil insulated wire wrapped around an iron core. A core of ferromagnetic material like
iron serves to increase the magnetic field. The strength of magnetic field generated is proportional to the amount of
current through the winding [2].
Solenoid is one of the applications of an electromagnet. When an electric current is passed through the coil windings, it
behaves like an electromagnet and the plunger which is located inside the coil is attracted towards the center of the coil
by magnetic flux setup within the coils body, which in turn compresses a small spring attached to one end of plunger.
The force produced by electromagnetic attraction is transmitted to the punching tool by means of push rod. When the
Volume 5, Issue 4, April 2017 Page 13

supply of current is turned OFF the electromagnetic field generated previously by the coil collapses and energy stored in
compressed spring forces the plunger back to its original rest position [1].
Figure 1 Construction of Solenoid [1]
3. DESIGN METHODOLOGY
3.1 CAD Modeling
The CAD model of existing machine is created. We studied the each part of the machine and understood the
importance of those parts. After analyzing, we determined to eliminate the unnecessary parts to reduce the cost of the
machine. The existing model is shown in figure 2.
Our aim is to fabricate the machine with lowest possible cost. To achieve the target we eliminate some of the
unnecessary parts. Instead of using two electromagnets we used only one. To maintain the desired force with one
electromagnet we increase the gauge of wire and no. of turns. The four push rods are replaced by only one push rod at
the center of punch plate. This also eliminates the magnetic plate. Also the four bolts and tapping operation on push
rods are saved. With this new model about 25% of total cost is saved which is economic. The modified design is shown
in figure 3.
Figure 2 CAD model of existing machine Figure 3 Modified Design Model

3.2 Analysis
We have done the static analysis to determine the optimum size of the frame. According to analysis point of view the
most important part of machine is punch plate. The punch plate is analyzed for allowable static deflection and
maximum stress for different sizes. The designed load is kept 1000N.
Figure 4 Deflection Figure 5 Stress

After too much iteration we selected the 200x200, 3mm thickness plate. The deflection and stress observed were
0.4861mm and 142.78N/mm2. Thus design is safe.
3.3 Design of Electromagnet
Here we used the solenoid type electromagnet. The electromagnetic force generated should be greater than the force
required to cut the material used.
Calculation of required force
Length of cut L= 25mm (assumed) Sheet thickness t= 0.3mm
t for aluminum= 110 N/mm2
Cutting force= 0.7*L*t*t= 0.7*25*0.3*110= 577.5N
Press force= 577.5N
Force produced (1)
Where B=Magnetic flux= (2)

A= Area of magnetic core
= Permeability of air
N= No. of turns
L= Length of core
I= Current
Assume, I=60 Amp L= 71mm
= 4*10-7 H/m
A=1075mm2
Now,
N= 1096.2 1100
Specifications of designed electromagnet:
1. No. of turns= 1100
2. Wire gauge= 22
3. Core area= 1075mm2
4. Length of core= 71mm
4. RELATION OF ELECTROMAGNETIC FORCE WITH CURRENT

The relation between the electromagnetic force and the current flowing through the coil is given by the equations (1)
and (2). From the above equations it can be seen that the Force (F) is directly proportional to the square of the current
(I). Also the force is directly proportional to the square of no. of turns (N) and inversely proportional to the length of
electromagnet. These parameters can be used for obtaining the required force for punching. By using these relations we
calculated the current required for punching various materials.
Sample calculation for aluminium sheet

Length of cut L= 25mm (assumed) Sheet thickness t= 0.1mm
for rubber= 26 N/mm2
Cutting force= L*t*= 25*0.1*26= 65N
From eq. (1)
Force produced F=
B= 0.3898 Wb/m2
From eq. (2)
Magnetic flux B=

I= 20.97 Amp
4.2 Values of current for different materials

Table 1: For Aluminium sheet (Shear strength= 180N/mm2)
Length of cut 25 25 25
Sheet thickness 0.1 0.2 0.3
Cutting force 450 900 1350
Value of current 55.18 78.03 95.56
Table 2: For Plastic sheet (Shear strength= 90N/mm2)

Table 3: For Rubber sheet (Shear strength= 26N/mm2)

The graphical representation of Force V/s Current curve is shown below.
Force V/s Current

2000
Force (F)
1000
Current(I)
Graph 1: Force V/s Current
Using the above relation we can control the force by controlling the current for different operations. Hence better
control on punch force and punch speed is achieved resulting in efficient operation.
5. EXPERIMENTAL SETUP
In the setup, an electromagnet is fixed on plywood sheet to insulate from the frame. The soft iron core i.e. armature of
electromagnet is attached to the punch plate at one end and another end is attached with the tool holder. The punch tool
is held by the tool holder. The helical compression springs are used for retracting the punch plate after punching is
done. The arrangement is done for die to fix on wooden block below the punch tool. The work piece is placed between
the punch and die. The electromagnet is connected to 230V A.C. supply in series with the switch, DIMMER and
ammeter. The dimmer is used to control the input current for electromagnet by simply changing the resistance to the
current. For measuring the value of current we used ammeter. When supply is given to the electromagnet, the armature
is pulled inside the core of electromagnet. This result into downward motion of both punch plate and tool and punching
operation is performed on work piece. The current is changed according to the operation by using the dimmer.

Figure 6 Arrangement for testing

5.1 Comparison of electricity consumption
The project model was compared with the mechanical press and hydraulic press for electricity consumption. All the
three machines were run for an hour one by one and the units consumed by each machines were observed and tabulated
for comparison. It has been observed that for same application, the electricity consumed by our machine was less as
compared to that of other machines.
Table 4: Comparison of power consumption
Duration of operation Units consumed
Machine
(hrs.) (kWh)
Mechanical press 1 2.46
Hydraulic press 1 4.1
Electromagnetic press 1 0.87
6. RESULTS
6.1 Percentage reduction in electricity consumption
1. Compared with mechanical press:
% reduction
2. Compared with Hydraulic press:
% reduction
6.2 Reduction in total cost
Sr. Cost in
Parts used Material Quantity
No. Rs.
Patented and cold

1 Spring 4 100
drawn steel
2 Electromagnet Std. 1 2400
Punch plate and electromagnet

3 EN-31 2 160
mounting plate
4 L shaped channels M.S. 2 410

5 Rod M.S. 1 100
6 Punch tools and die HCHCr 5 2200
7 Metal strip 12x3mm M.S. 1 100
8 Plywood 15mm thick Wood 1 100
9 Plywood 4mm thick Wood 1 50
10 Electrical components Std. - 250
11 Nuts, Bolts and Accessories Std. - 200
12 Fabrication expenses - - 400
Total 6470
The reduction in cost of the machine is achieved so it can be used for small scale industry economically.
6.3 Final product produced
Figure 7 Washers
7. CONCLUSION
By implementing this new concept in sheet metal operation, we concluded that the machine is economical for small
scale industry. It is very flexible process in which the capacity of machine can be changed by changing the
electromagnet only. The power consumption is less as compared to conventional machine for same size of the product
resulting into efficient operation. By changing the value of current supplied the force generated can be varied according
to the operation. Due to increased punch speed the quality of the product is improved. From the above conclusions the
overall cost of the product can be reduced.
References
[1] AMAE Int. J. on Manufacturing and Material Science, Vol. 01, No. 02, November 2011
[2] http://www.electronics-tutorials.ws/io/io_6.html
[3] International Engineering Research Journal (IERJ), Volume 2 Issue 7 Page 2417-2422, 2017 ISSN 2395-1621
[4] International Journal of Modern Trends in Engineering and Research (IJMTER)
Volume 2, Issue, [July - 2015] Special Issue of ICRTET2015
[5] IJARIIE-ISSN(O)-2395-4396 Vol-2 Issue-6 2016
[6] AMAE Int. J. on Manufacturing and Material Science, Vol. 01, No. 02, November 2011

[7] International Journal on Recent and Innovation Trends in Computing and Communication Volume: 4 Issue: 4
ISSN: 2321-8169 354 356
[8] www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 4, April 2015)
[9] www.ijmer.com (IJMER ISSN: 22496645 Vol. 5, Iss. 7, July 2015, 30)
[10] International Journal of Modern Trends in Engineering and Research (IJMTER)
Volume 2, Issue, [July - 2015] Special Issue of ICRTET2015
[11] International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394
3386 Volume 2 Issue 2 February 2015
AUTHOR
Abhishek Rane received the B.E. degree in Automobile Engineering from Rajendra Mane College of Engineering
and Technology in 2009. He completed the M.E. in Machine Design-Mechanical from FAMT, Ratnagiri in 2017.

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IPASJ International Journal of Mechanical Engineering (IIJME)

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Volume 5, Issue 4, April 2017 Page 13

Figure 1 Construction of Solenoid [1]

Figure 2 CAD model of existing machine Figure 3 Modified Design Model

Figure 4 Deflection Figure 5 Stress

Volume 5, Issue 4, April 2017 Page 14

Where B=Magnetic flux= (2)

4. RELATION OF ELECTROMAGNETIC FORCE WITH CURRENT

Sample calculation for aluminium sheet

Volume 5, Issue 4, April 2017 Page 15

4.2 Values of current for different materials

Table 2: For Plastic sheet (Shear strength= 90N/mm2)

Table 3: For Rubber sheet (Shear strength= 26N/mm2)

The graphical representation of Force V/s Current curve is shown below.

Force V/s Current

Volume 5, Issue 4, April 2017 Page 16

Figure 6 Arrangement for testing

Hydraulic press 1 4.1

Electromagnetic press 1 0.87

6.2 Reduction in total cost

Patented and cold

2 Electromagnet Std. 1 2400

Punch plate and electromagnet

4 L shaped channels M.S. 2 410

Volume 5, Issue 4, April 2017 Page 17

5 Rod M.S. 1 100

6 Punch tools and die HCHCr 5 2200

7 Metal strip 12x3mm M.S. 1 100

8 Plywood 15mm thick Wood 1 100

9 Plywood 4mm thick Wood 1 50

10 Electrical components Std. - 250

11 Nuts, Bolts and Accessories Std. - 200

12 Fabrication expenses - - 400

6.3 Final product produced

Volume 5, Issue 4, April 2017 Page 18

Volume 5, Issue 4, April 2017 Page 19

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