In this research the designed mechanism for chasing and repoussé of sheet metal is studied. This mechanism is similar to incremental sheet metal forming. In this kind of sheet metal forming, sheet is fixed and forming tool pastes desired pattern incrementally. The major difference between designed mechanism and traditional incremental forming is as follows: control on the punch energy and sequence, and fixing sheet by using protectant material behind it instead of clamping sheet sides. In this mechanism, the solenoid is used as a hammer. The plunger moves to the center of the coil while energized. Striking energy could be controlled by controlling the excitement voltage and punching sequence thus could be adjusted by manipulating the excitement algorithm. In this paper, the utilized solenoid is simulated. The mechanical and magnetic relations are merged for this. And the effect of core head geometry and plunger mass and coil covers on the strike energy and hence power is studied.

Keywords: Incremental sheet metal forming, magnetic hammer, chasing and repoussé, prototyping

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