Electromagnetic wires, as various driving electrical components, are prone to stress concentration and fracture failure during the forming process due to their stacked structure. This article studies the mechanical properties of the loading sequence of tension bending and torsion bending combined working conditions in electromagnetic wire forming. Multiple load tests and simulations were used to describe the mechanical evolution of different loading sequences. X-ray diffraction and electron microscopy were used to analyze residual stress and characterize the microstructure of insulation damage. The influence of loading sequence on the mechanical behavior of electromagnetic wires and the damage of PI insulation layer was studied. The results indicate that the stress concentration area is smaller in the working condition of simultaneous twisting and bending, and the residual stress is lower compared to other working conditions. The condition of stretching first and then bending has lower residual stress compared to other conditions. Optimizing working conditions can reduce the risk of insulation damage.
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