Hemming of Aluminum Alloy Sheets Using Electromagnetic Forming

Hemming is usually the last stage of production for automotive closures, and therefore has a critical effect on the quality of the final assemblies. The insufficient formability of aluminum alloys creates a considerable problem in the hemming process. To address this issue, electromagnetic forming was utilized to hem aluminum alloy sheets. Electromagnetic forming is a high strain rate forming process that is currently being investigated by both academia and industry. Past studies have shown that the formability of metals can be significantly improved during electromagnetic forming, which benefits the hemming of aluminum alloys. This article presents the experimental results of hemming Al 6061-T6 sheets using electromagnetic forming. The effects of the parameters of electromagnetic hemming on the hem quality are discussed. In addition, the numerical simulation results of electromagnetic hemming are presented to enhance the understanding of the process and to determine the efficacy on an industrial scale.