Abstract:This work is aimed to investigate time-spatial distribution rules and the effect of process parameters and geometric parameters to the forming quality of CLA16 F/M steel manufactured by electromagnetic incremental forming. Based on LS-Dyna R8.0 platform, an electromagnetic field-structure field sequential coupled finite element-boundary element model of electromagnetic incremental forming process of dummy fuel element was established. With the aid of the numerical simulation model, the electromagnetic forming process of dummy fuel element under different discharging voltages, flyer tube-base tube clearances and wall thickness of flyer tube were simulated and analyzed, and the sample fuel element was manufactured, for the sake of studying the local plastic flow rules, defects generation rules and characterizing the forming quality. Results show that oversized discharging voltage brings about the concentration of deformation zones to both ends of the tube. Also, the collision between the flyer tube and the base tube is aggravated and section distortion is introduced. Undersized discharging voltage can not generate the collision, deformation and sticking and thus leads to disconnection. Appropriate adjusting the clearance between base tube and flyer tube can effectively avoid wrinkling and nonuniformity of wall thickness. By comprehensive optimization of process parameters, through-process high quality precise forming of defects control of dummy fuel element was realized and the sticking precision between base tube and flyer tube reaches 10μm.