Recent years have witnessed the rapid development of electromagnetic flanging of tubes, which uses coils to generate electromagnetic forces to achieve the deformation with high speed but without contact. However, the electromagnetic force decays dramatically with the increase of distance, resulting in strict requirements of geometrical matching between the coils and the tubes. Usually, new coils should be fabricated for tubes with new sizes, which is inconvenient and uneconomical. Therefore, a more flexible and economical method is proposed in this paper, which introduces a solenoid field shaper into the existing electromagnetic flanging system. By adjusting the structure and the position of the field shaper, the distribution of electromagnetic forces can be reshaped to form tubes with various sizes, without changing the coil, whose cost is much higher than a field shaper. The principle of this method is introduced in detail. Then, an electromagnetic-structure coupled finite element simulation model is established to calculate the forming process. The results show that when forming an A6063-T83 aluminum alloy tube with an inner diameter of 110mm, the discharge voltage can be tuned down from 5.3kV, without field shaper, to 4.6kV, with field shaper. That means the energy consumption of the system can be saved by 25%, and the manufacturing process of the field shaper is simpler than that of the forming coil. What’s more, when forming tubes with different sizes, the new method shows higher effectiveness, greater flexibility, and lower cost than the traditional way.

近年来，管材电磁翻边技术发展迅速，是利用线圈产生电磁力，实现无接触高速变形。然而，电磁力随着距离的增加而急剧衰减，从而对线圈和管子之间的几何匹配提出了严格的要求。通常，对于新尺寸的管子，要制作新的盘管，既不方便也不经济。因此，本文提出了一种更灵活、更经济的方法，将电磁场整形器引入现有的电磁翻边系统。通过调整场整形器的结构和位置，可以重新整形电磁力的分布，形成各种尺寸的管子，而无需改变线圈，其成本远高于场整形器。详细介绍了该方法的原理。然后，建立电磁-结构耦合有限元仿真模型，计算成形过程。结果表明，成型内径为110mm的A6063-T83铝合金管时，放电电压可从无场整形器的5.3kV调低至有场整形器的4.6kV。这意味着该系统的能耗可以节省25%，并且场成形器的制造工艺比成形线圈的制造工艺更简单。更重要的是，在成型不同尺寸的管子时，新方法比传统方法显示出更高的效率、更大的灵活性和更低的成本。建立电磁-结构耦合有限元仿真模型，计算成形过程。结果表明，成型内径为110mm的A6063-T83铝合金管时，放电电压可从无场整形器的5.3kV调低至有场整形器的4.6kV。这意味着该系统的能耗可以节省25%，并且场成形器的制造工艺比成形线圈的制造工艺更简单。更重要的是，在成型不同尺寸的管子时，新方法比传统方法显示出更高的效率、更大的灵活性和更低的成本。建立电磁-结构耦合有限元仿真模型，计算成形过程。结果表明，成型内径为110mm的A6063-T83铝合金管时，放电电压可从无场整形器的5.3kV调低至有场整形器的4.6kV。这意味着系统的能耗可以节省25%，并且场成形器的制造工艺比成形线圈的制造工艺更简单。更重要的是，在成型不同尺寸的管子时，新方法比传统方法显示出更高的效率、更大的灵活性和更低的成本。放电电压可以从不带场整形器的 5.3kV 调低到带场整形器的 4.6kV。这意味着该系统的能耗可以节省25%，并且场成形器的制造工艺比成形线圈的制造工艺更简单。更重要的是，在成型不同尺寸的管子时，新方法比传统方法显示出更高的效率、更大的灵活性和更低的成本。放电电压可以从不带场整形器的 5.3kV 调低到带场整形器的 4.6kV。这意味着该系统的能耗可以节省25%，并且场成形器的制造工艺比成形线圈的制造工艺更简单。更重要的是，在成型不同尺寸的管子时，新方法比传统方法显示出更高的效率、更大的灵活性和更低的成本。