Electromagnetic Forming & High-Velocity Joining

Magnetic Pulse Crimping & Swaging Prepress Calculator

Determine RLC capacitor bank peak discharge currents, high-frequency Lorentz radial compressive pressures, flyer impact velocities, and joint pull-out shear strength for automotive, aerospace, and high-voltage cable swaging.

Process Parameters & Inputs

Discharge Charging Voltage (V_0):

Capacitor bank charging voltage in kilovolts (kV).

Capacitor Bank Capacitance (C_bank):

Discharge bank total capacitance in microfarads (µF).

Outer Tube Wall Thickness (t_tube):

Conductive flyer tube wall thickness (Al/Cu) in mm.

Radial Acceleration Standoff Gap (g_gap):

Radial air gap between outer tube and inner mandrel in mm.

Crimp Engagement Length (L_crimp):

Axial engagement length of the swaged joint in mm.

Calculated Engineering Metrics

Peak Discharge Current

145kA

Lorentz Magnetic Pressure

280MPa

Tube Flyer Velocity

240m/s

Joint Pull-Out Retention

18.5kN

Toolpath & Geometry Simulation

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Engineering Principles & Formula Reference

Magnetic Pulse Crimping (MPC) is a contactless, solid-state forming process that utilizes pulsed Lorentz magnetic pressures ($P_{mag} = \frac{B^2}{2\mu_0}$) generated by a field shaper coil to radially compress tubular workpieces at supersonic velocities.

Lorentz Pressure & Pull-Out Retention:

I_{peak} = V_0 \cdot \sqrt{\frac{C_{bank}}{L_{system}}} \cdot \exp\left(-\frac{R}{2L} t_{peak}\right)
P_{mag} = \frac{(\mu_0 n I_{peak})^2}{2 \mu_0}
v_{flyer} = \sqrt{\frac{2 P_{mag} \cdot g_{gap}}{\rho_{tube} \cdot t_{tube}}}
F_{pull} = 2 \pi R_{inner} \cdot L_{crimp} \cdot \tau_{shear}

Eliminates heat-affected zones, flux residues, and mechanical tool wear, producing gas-tight hermetic seals with higher shear strength than conventional mechanical crimping.