  Electromagnetic forming and perforations (EMFP) are complex and innovative
high strain rate processes that involve electromagnetic-mechanical interactions
for simultaneous metal forming and perforations. Instead of spending costly
resources on repetitive experimental work, a properly designed numerical model
can be effectively used for detailed analysis and characterization of the
complex process. A coupled finite element (FE) model is considered for
analyzing the multi-physics of the EMFP because of its robustness and improved
accuracy. In this work, a detailed understanding of the process has been
achieved by numerically simulating forming and perforations of Al6061-T6 tube
for 12 holes and 36 holes with two different punches, i.e., pointed and concave
punches using Ls-Dyna software. In order to shed light on EMFP physics, a
comparison between experimental data and the formulated numerical simulation
has been carried out to compare the average hole diameter and the number of
perforated holes, for different types of punches and a range of discharge
energies. The simulated results show acceptable agreement with experimental
studies, with maximum deviations being less than or equal to 6%, which clearly
illustrates the efficacy and capability of the developed coupled Multi-physics
FE model.
