IJSRSET196544 | Received : 01 Oct 2019 | Accepted : 15 Oct 2019 | September-October-2019 [ 6 (5) : 167-171 ] © 2019 IJSRSET | Volume 6 | Issue 5 | Print ISSN: 2395-1990 | Online ISSN : 2394-4099 Themed Section : Engineering and Technology DOI : https://doi.org/10.32628/IJSRSET 167 Finite Element Simulation of Electro Magnetic Welding with Varying Air Gap A.Surendra 1 , S. Jithendra Naik 2 , L. Balasubramanyam 1 M.Tech Student, CAD/CAM, Department of Mechanical Engineering, PVKK Institute of Technology, Ananthapuramu, Andhra Pradesh, India 2 Associate Professor, Department of Mechanical Engineering, PVKK Institute of Technology, Ananthapuramu, Andhra Pradesh, India 3 HOD & Associate Professor, Department of Mechanical Engineering, PVKK Institute of Technology, Ananthapuramu, Andhra Pradesh, India ABSTRACT Magnetic pulse welding process, one of high speed welding processes, uses electromagnetic force from discharged current through a working coil which develops a repulsive force between the induced currents flowing parallel and in the opposite direction in the work piece to be welded. Coils of specific geometry and material combinations are essentially required to achieve precise and successful electromagnetic (EM) welding. The aim of the present research is to assess the weldability criteria of high speed magnetic pulse welding for tubular jobs of Al, Cu and SS combinations using finite element analysis. A circular design of EMW coil is proposed to perform EMW simulations while varying the air gap between the outer tube and inner tube of different work pieces and voltages. A 3-dimensional electromagnetic FE-model has been developed to analyze the distribution of electromagnetic force and magnetic flux density. Results of electromagnetic forces and magnetic flux density acquired during EMW simulations of various material combinations are shown here. The data shown in the results provides a guideline to choose EM welding parameters for further experimentations. The demonstrated results will assist future researchers to develop a better methodology for coil design and to further explore the field Keywords : EMW, CATIA,FEA,ANSYS, FE-model, Electromagnetic I. INTRODUCTION Welding, as existing fusion welding, generally causes not only defects, such as solidification, cracking, porosity and oxidation, but also transformation and corrosion. For this reason, more attention has been paid to magnetic pulse welding process as a kind of solid-state welding, these days. Electromagnetic (EM) welding is an impact welding process of joining two similar or dissimilar metals by removing oxide layer and by creating a high velocity impact by Lorentz forces generated due to the electromagnetic field and damped sinusoidal transient current. It offers many distinct advantages, provided it is used, taking into account its limitations. continuously as a function of position along certain dimension (typically the radius and thickness) of the structure to achieve a require function. FGMs can provide designers with tailored material response and exceptional performance in thermal environments. For example, the Space