Electrically assisted manufacturing （EAM）is a promising and rapidly developing metal processing method.The power supply is a key sub-system for EAM，which needs to be designed properly.the model-based design of a low-voltage high-current pulse power supply used for EAM was proposed based on converter-level electro-thermal modeling.The thermal stress of key components was obtained by converter-level finite element simulations.A simplified thermal modeling method was proposed to reduce the computation burden of the finite element modeling（FEM） simulation to obtain the dynamic thermal profile under pulse current operation.The impact of the duration of the current pulse on the maximum temperature and temperature variations of MOSFETs was investigated based on the thermal model.A case study of a 10 V/500 A pulse power supply was presented to demonstrate the theoretical analyses and verification. The outcomes contribute to the design optimization and virtual prototyping of pulse power supplies for EAM applications.

electrically assisted manufacturing（EAM）  /  finite element analysis  /  thermal model  /  virtual prototyping