This paper proposes an innovative electromagnetic forming process for the manufacturing of aluminum alloy tubes, namely electromagnetic impacting medium forming (EIMF) process using flat spiral coil. The proposed EIMF process was implemented and characterized by numerical and experimental methods. Based on medium height and discharge energy, deformation region of tube was analytically determined and verified by finite element (FE) analysis. Effects of medium height and discharge energy for maximum diameter and strain rate of deformation tube were characterized numerically and experimentally. Flow defect of medium was observed at higher discharge energy. To estimate the effect of capacitance, four types of capacitance were designed and evaluated by numerical analysis. Through EIMF experiments, tubes with temperature from 25 °C to 200 °C were investigated and variations of maximum diameter (expansion ratio), thickness (thinning ratio) were obtained. Comparing with results under discharge energy, temperature has more obvious effects. Major and minor strains displayed higher level at 200 °C. Metallographic and morphologies were characterized by optical microscope (OM) and scanning electron microscopy (SEM). Results showed that refinement of average grain size and ductile fracture depends on the increase of discharge energy and temperature.

本文提出了一种创新的用于铝合金管制造的电磁成型工艺，即使用扁平螺旋线圈的电磁冲击介质成型（EIMF）工艺。拟议的EIMF工艺已通过数值和实验方法实施并表征。基于介质的高度和放电能量，通过有限元分析确定并验证了管的变形区域。数值和实验表征了介质高度和放电能量对变形管最大直径和应变率的影响。在较高的放电能量下观察到介质的流动缺陷。为了估计电容的影响，设计了四种类型的电容，并通过数值分析对其进行了评估。通过EIMF实验，研究了温度从25°C到200°C的试管，并获得了最大直径（膨胀比），厚度（稀化比）的变化。与放电能量下的结果相比，温度的影响更为明显。主应变和次应变在200°C时显示较高水平。用光学显微镜（OM）和扫描电子显微镜（SEM）对金相和形貌进行表征。结果表明，平均晶粒尺寸和韧性断裂的细化取决于放电能量和温度的增加。用光学显微镜（OM）和扫描电子显微镜（SEM）对金相和形貌进行表征。结果表明，平均晶粒尺寸和韧性断裂的细化取决于放电能量和温度的增加。用光学显微镜（OM）和扫描电子显微镜（SEM）对金相和形貌进行表征。结果表明，平均晶粒尺寸和韧性断裂的细化取决于放电能量和温度的增加。