Electromagnetic actuators alter strain distribution in sheet metal.

The Need

Metal stamping industry operators with the greatest potential for growth are those that supply high growth and value-added manufacturing industries such as private aerospace manufacturing. Manufacturers will benefit from adopting new alloys (titanium alloys in particular) to develop castings with enhanced qualities, such as those with lower weight, greater strength, corrosion resistance and temperature resistance characteristics. These alloys require precise manufacturing techniques most important of which involves validating material uniformity and durability. Suppliers of clients that demand high-quality components, such as aerospace or transport equipment manufacturers, must adopt techniques that ensure the uniform fabrication of metals in any variety of required geometries.

The Market

  • The Metal Stamping & Forging industry is predicted to grow at an annualized 4.4% until 2019, bringing revenue to $48.1 billion. Profitability will be highest among metal stampers and forgers supplying high-technology markets, such as aerospace, since these markets pay price premiums for custom made purchases. (IBISWorld)
  • TechNavio’s analysts forecast the Metal Stamping industry in the US to grow at a Compound Annual Growth Rate (CAGR) of 7.91% from 2012 to 2016. One of the key factors contributing to this growth is the growing demand from the Automotive industry.
  • Actuators and motors make up the largest application segment of the smart materials market, with sales of nearly $10.8 billion (55% of the total market) in 2010, increasing to $25.4 billion (nearly 64% of the market) by 2016, a CAGR of 15.4% between 2011 and 2016 (Smart Materials & Applications – BCCresearch).

The Technology

The Ohio State University researchers, led by Dr. Glenn S. Daehn, developed a method of using electromagnetic actuators inside conventional sheet stamping tools to fabricate a variety of components. Current methods of stamping metal induce stress on the material and create wrinkles. This method of using electromagnetic actuators for metal stamping suppresses these faults and allows for greater strain distribution and more advanced components to be formed. The technology consists of an electromagnetic actuator formed in different geometries and utilizes a magnetic field. This field will generate repulsive forces between the actuator and the target metal to create the desired geometry.Dr. Daehn has an issued patent 6,128,935 protecting this technology.

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