Electromagnetic calibration is a new method to eliminate or reduce springback in sheet metal forming processes, which, despite the investigations that have been done so far, still needs more research to improve efficiency and ease of use. The present research improved this method for both aspects with a magnetic core for the tool coil. Firstly, an electromagnetic calibration method that uses a non-cored tool coil was simulated by the finite element method (FEM) and validated by the available experimental data. Afterward, the new method with an improved tool coil is introduced and simulated by the FEM model. The results show that the new tool coil significantly improves the efficiency of the electromagnetic calibration operation. When the experimental tests were done using the new tool coil, which was made using a magnetic core, bending angles similar to those reported in similar studies were obtained by spending about 40 % less energy on average. Due to the concentration of the magnetic field, its unwanted effects on the die components were not noticeable, and no distortion was seen in the parts. In addition, the new tool coil allows calibration operations to be performed during the bending process without changing the geometry or material of the die components, which is difficult, if not impossible, with coreless ones.
