A technique for machining thin metallic foils using electromagnetic mechanical pulsed loading

Sharma, D and Dutta, I and Kumar, P (2020) A technique for machining thin metallic foils using electromagnetic mechanical pulsed loading. In: Engineering Research Express, 2 (1).

PDF Tec_Man_Thi_2020.pdf - Published Version Restricted to Registered users only Download (938kB) | Request a copy

Abstract

Short duration electric current pulses of large current densities(>109Am-2) generate electromagnetic forces that can propagate a crack in a thin metallic foil. If a far-field mechanical load is also applied in conjunction with these electromagnetic forces then the rate and the direction of crack propagation can be precisely controlled by manipulating the pulse-width and magnitude of the electric current pulse, and the magnitude and direction of the applied mechanical load. Here, we exploit such correlations to develop a tool-less technology for machining thin metallic foils (10-100 μm) and demonstrate its efficacy by cutting a 12 ìmthick Al foil by propagating a pre-existing sharp notch along a preset locus. Finite element method (FEM) was employed to predict the cutting criteria, i.e., the onset of crack propagation and the angle of cutting in terms of crack deflection due to application of an electric current pulse and a static mechanical loading simultaneously. Experiments conducted with cutting parameters suggested by FEM simulations showed that the proposed machining tool was able to make precise cuts in Al foil along a user-defined path with high resolution

Item Type:	Journal Article
Publication:	Engineering Research Express
Publisher:	IOP Publishing Ltd
Additional Information:	The copyright for this article belongs to the IOP Publishing Ltd.
Keywords:	Aluminum foil; Crack propagation; Electric currents; Finite element method, Crack deflections; Cutting parameters; Electric current pulse; Electromagnetic forces; Large current density; Mechanical loads; Static mechanical loading; Thin metallic foils, Cracks
Department/Centre:	Division of Mechanical Sciences > Materials Engineering (formerly Metallurgy)
Date Deposited:	01 Feb 2023 12:04
Last Modified:	01 Feb 2023 12:04
URI:	https://eprints.iisc.ac.in/id/eprint/79693

Actions (login required)

View Item