This study presents mathematical modeling and calculation procedure for problems of electromagnetic forming of thin circular metal sheets using a flat spiral coil as actuator. The methodbased on the Biot-Savart Law focuses specifically on the calculation of the electromagnetic field generated by the flat coil and analysis of the circuit that models the electromagnetic forming system to the initial time, before the plastic deformation of the sheet. The solution of magnetic induction integral equations is performed by numerical methods specifically with the use of Matlab® software, providing important information that serves as feedback for system design. Free bulging experiments were performed to demonstrate a good relationship with the mathematical model predictions for electrical discharge current in the coil and induced currents in the metal sheet, behavior of the transient electromagnetic force between coil and workpiece, and distribution of magnetic field, electromagnetic density force along the coil.

Electromagnetic forming (EMF) is a high-speed forming process that uses energy density of a pulsed magnetic field to deform metallic workpieces. This paper presents a method to calculate the electromagnetic force in thin flat plates using a flat spiral coil as an actuator. The method is based on the Biot-Savart law, and the solution of magnetic induction integral equations is performed inside Matlab^® by a numerical method based on discretizing the EMF system in a system of ordinary differential equations that couple the electric and magnetic phenomena. Free bulging experiments and a comparison with Ansoft Maxwell^® software are presented demonstrating a good correlation with the proposed implementation.

In this study, an experimental and statistic investigation approach based on analysis of variance (ANOVA) and response surface methodology (RSM) techniques was performed to find the significant main effects and two-factor interaction effects and to determine how the controllable factors such as cutting speed, feed rate, depth of cut (DOC), tool nose radius, substrate and coating method of cutting tools influence surface quality in turning of AISI 1045 steel. The first optimal or near-optimal conditions for the quality of the generated surface and the second ones, including maximum material removal rate, were established using the proposed regression equations. The group mean roughness of the turned workpieces was lower from using chemical vapor deposition (CVD)-coated carbide inserts than the group means of other types of inserts; however they could not achieve the specific lowest roughness. The physical vapor deposition (PVD)-coated carbide and cermet inserts achieved the best surface quality when the specific combinations within the range interval of controllable factors were used in the experiment, showing that they may be applied to finish turning processes or even to particular high material removal rate conditions associated with the lowest roughness.