Apparatus for electromagnetically forming a workpiece

1. An apparatus for electromagnetically forming a workpiece, the apparatus comprising:

a solenoid coil for generating an electromagnetic field; and

a tool for concentrating the electromagnetic field to exert pressure against the workpiece, the tool including:

an electrically conductive body having a first surface, a second surface, and an aperture having a generally T-shaped configuration extending between the first and second surfaces; and

an insulator disposed in the aperture, the insulator directing current around the aperture to distribute the pressure for forming the workpiece.

2. The apparatus of claim 1 wherein the insulator is air.

3. The apparatus of claim 1 wherein the insulator is an electrically nonconductive material that fills the aperture to structurally reinforce the tool.

4. The apparatus of claim 1 wherein the aperture includes an aperture wall extending between the first and second surfaces, the aperture wall having a serpentine configuration that increases a current flow path through the electrically conductive body and toward a working surface disposed proximate an end of the tool facing the workpiece.

5. The apparatus of claim 1 wherein the tool further comprises an end surface for applying electromagnetic pressure to the workpiece.

6. The apparatus of claim 5 wherein the aperture further comprises an aperture wall and wherein the end surface and a portion of the aperture wall disposed closest to the end surface are curved.

7. The apparatus of claim 1 wherein the insulator reinforces the tool to withstand load forces.

8. The apparatus of claim 7 wherein the aperture further comprises an aperture wall, at least a portion of the aperture wall having a serpentine configuration that increases a current flow path through the electrically conductive body and toward a working surface disposed proximate an end of the tool.

9. The apparatus of claim 1 wherein the tool further comprises an end surface and a recess that extends from the aperture toward the end surface.

10. The apparatus of claim 9 wherein the recess extends from the first surface toward the second surface and wherein the insulator at least partially fills the recess.

11. The apparatus of claim 1 wherein the electrically conductive body further comprises an end feature made of a material having higher conductivity than an adjacent portion of the electrically conductive body to facilitate the distribution of pressure for forming the workpiece.

12. An apparatus for electromagnetically forming a workpiece, the apparatus comprising:

a solenoid coil for generating an electromagnetic field; and

a tool for concentrating the electromagnetic field provided by the solenoid coil to exert force against the workpiece, the tool including:

an electrically conductive body having a first surface, a second surface disposed opposite the first surface, an aperture extending between the first and second surfaces and having an aperture wall at least a portion of which has a serpentine configuration, and an end surface for applying electromagnetic force to the workpiece; and

an insulator disposed in the aperture;

wherein the aperture and the insulator cooperate to increase a current flow path through the electrically conductive body to facilitate electromagnetic forming of the workpiece.

13. The apparatus of claim 12 wherein the aperture is defined by an aperture wall having a serpentine configuration that increases the current flow path through the electrically conductive body and toward a working surface disposed proximate an end of the tool facing the workpiece.

14. The apparatus of claim 12 wherein the tool further comprises a recess extending from the aperture toward the end surface.

15. The apparatus of claim 14 wherein the recess extends from the first surface toward the second surface and wherein the insulator at least partially fills the recess.

16. An apparatus for electromagnetically forming a workpiece, the apparatus comprising:

a multi-turn solenoid coil for generating an electromagnetic force; and

a tool disposed proximate the multi-turn solenoid coil for concentrating electromagnetic force provided by the multi-turn solenoid coil against the workpiece, the tool including:

an electrically conductive body having a first surface, a second surface, an aperture extending between the first and second surfaces, and an end portion disposed adjacent to the aperture, the end portion having an exterior surface for applying electromagnetic force to the workpiece, and a recess disposed adjacent to the aperture and extending partially through the electrically conductive body such that the recess is spaced apart from the exterior surface; and

an insulator disposed in the aperture, the insulator directing current around the aperture;

wherein the aperture and recess cooperate to increase a current flow path through the electrically conductive body to facilitate electromagnetic forming of the workpiece.

17. The apparatus of claim 16 wherein the aperture is defined by a serpentine aperture wall that extends around the aperture.

18. The apparatus of claim 16 wherein the electromagnetic body further comprises a cavity disposed adjacent to the end surface, the cavity having a generally semicircular shape.

19. The apparatus of claim 18 wherein the aperture includes first and second extension portions spaced apart from the cavity and extending toward the end portion such that the first and second extension portions are disposed on opposite sides of the cavity.

20. The apparatus of claim 16 wherein the insulator reinforces the tool to withstand load forces.

21. An apparatus for electromagnetically forming a workpiece, the apparatus comprising:

a solenoid coil for generating an electromagnetic field; and

a tool for concentrating the electromagnetic field to exert pressure against the workpiece, the tool including:

an electrically conductive body having a first surface, a second surface, and an aperture extending between the first and second surfaces; and

an insulator disposed in the aperture, the insulator directing current around the aperture to distribute the pressure for forming the workpiece, wherein the insulator structurally reinforces the tool.