Real-time and selective control of shell deformation based on dynamic and subregional pressure response of flexible dies under magnetic field

• Published in: International journal of advanced manufacturing technology 2024-02, Vol.130 (9-10), p.5003-5024
• Main Authors: Xiang, Nan, Wang, Hao-ran, Wang, Peng-yi, Huang, Tao, Guo, Jun-qing, Wang, Yao-li, Chen, Fu-xiao
• Format: Article
• Language: English
• Subjects: CAE) and Design; Computer-Aided Engineering (CAD; Controllability; Die forming; Dynamic pressure; Elastic deformation; Elastomers; Engineering; External pressure; Flux density; Industrial and Production Engineering; Iron; Magnetic fields; Magnetic flux; Magnetic properties; Mechanical Engineering; Media Management; Metal sheets; Original Article; Particulate composites; Rheological properties
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-024-13040-w

Pressure-carrying properties of traditional flexible dies can hardly be controlled during the forming process of shell components. In this work, a forming method based on the subregional and dynamic pressure response of flexible die was proposed, aiming at achieving the flexible control of shell deformation in different forming regions and stages. Elastic composites with iron particles selectively dispersed in pre-designed location, i.e., heterogeneous magneto-rheological elastomers (MREs), were fabricated and employed as the flexible dies in the bulge tests of Al1060 sheet in the presence of external magnetic field. Shell deformation were dynamically measured, pressure field and stress state were numerically studied. The results showed that local shell deformation could be controlled in a nearly monotonic way by adjusting the distribution pattern and content ( φ ) of iron particles. In the case that heterogeneous MRE with φ = 0/30% was employed and magnetic field with flux density ( B ) of 1950 Gs was applied, difference of bulge height and strain on both sides of the deformed shell increased by 6.5% and 16%, respectively. The maximum difference of bulge height on both sides of the sheet metal appeared in the case that B = 1240 Gs, which showed an increase of 9% compared with the condition that no magnetic field is applied. But, the influence of magnetic field is not monotonous. Changed stress paths of sheet metal, which was induced by non-uniformly distributed and dynamically controllable pressure field of heterogeneous MREs, was used to clarify the forming mechanism.