Mechanism of magnetic field condition on deformation behavior of sheet metal using a property-adjustable flexible-die

Wang, Pengyi; Wang, Zhongjin; Xiang, Nan; Cai, Shupeng; Li, Zexin

doi:10.1007/s00170-020-05712-0

Cited by 9 publications

(5 citation statements)

References 22 publications

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“…Taking 23 measuring points which are distributed in the section of the deep-drawn part, the wall thickness distribution of the deep-drawn parts with different forming conditions are measured as shown in Figure 14(a). The formed parts is divided into three areas: straight wall area (measuring points 1-6), die radius area (measuring points 6-9) and bottom area (measuring points [9][10][11][12]. The trend of wall thickness distribution is roughly the same because the section of the parts are symmetrial.…”

Section: Analysis Of Formed Partsmentioning

confidence: 99%

“…Wang et al 10 applied MR fluid as soft mold in the bulging forming process. Wang et al [11][12][13] studied the influence of variable magnetic field conditions on sheet bulge forming performance with MR fluid as a flexible media by changing the loading path, and the effect about the properties of forming media on the deformation behavior of sheet metal under different magnetic fields. The results showed that MR fluid can respond quickly to the change of magnetic field and sheet forming performance was significantly improved.…”

Section: Introductionmentioning

confidence: 99%

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A novel process of sheet metal inverse bulging pre-deformation for deep drawing forming using magnetorheological fluid as flexible media

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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At the Magnetic field condition, the surface quality of formed parts can be improved significantly. To investigate the technical advantages of Magnetorheological (MR) fluid as a soft media, eliminate the defects of the parts because of the complex deformation, such as wrinkling, cracking, and over thinning. A new method of sheet deep drawing forming with MR fluid through inverse bulging pre-forming was proposed, which has made the wall thickness distribution more uniform and changed the stress distribution of sheet by changing the rheological property of MR fluid. The theoretical pressure transfer model of MR fluid as media and the configuration model of inverse bulging pre-forming are established. It can be concluded that the relationship between bulge height and load time have been shown consistency compared with experimental results and agree well with the theoretical analysis. And the configuration model have shown good agreement from the experiments results and the numerical results espectively with theoretical results. The uniformity of the wall thickness and the surface quality of the deep-drawn parts are improved significantly with the increase of the inverse bulging height. When the inverse bulging height is about 9 mm, the pre-forming effect is optimal, which provides theoretical guidance and is of much potential to the forming of the and thin-walled complex parts in industry fields.

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Section: Analysis Of Formed Partsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A novel process of sheet metal inverse bulging pre-deformation for deep drawing forming using magnetorheological fluid as flexible media

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Besides, when magnetic eld was applied in the ange area, the sealing limit was effectively improved and the forming height of the cup-shaped specimen was greater than that of the specimen formed by mineral oil [10]. Some researchers investigated the effects of B on the formability of sheet metal through bulge tests and found that formability and stress state of sheet metal could be signi cantly improved by controlling the ux density of external magnetic eld [11][12][13][14]. Li et al [15,16] further used MRF as the back pressure-carrying medium in deep drawing of stainless steel sheet.…”

Section: Introductionmentioning

confidence: 99%

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

Xiang,

Wang,

Wang

et al. 2024

Int J Adv Manuf Technol

Self Cite

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Pressure-carrying properties of traditional exible materials can hardly be controlled during the process that they serve as pressure-carrying medium to form shell components. In this work, a forming method based on the subregional and dynamic pressure response of property-adjustable forming medium was proposed, aiming at achieving the exible control of shell deformation in different 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 exible dies in the bulge tests of Al1060 sheet in the presence of external magnetic eld. Deformation behaviors of sheet metal were dynamically measured, and loading and stress conditions 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 eld with ux 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. In the presence of magnetic eld with B = 1240Gs, difference of bulge height on both sides of the sheet metal increased by 9% compared with the condition that no magnetic eld is applied. But, the in uence of magnetic eld is not monotonous. Changed stress paths of sheet metal, which was induced by non-uniformly distributed and dynamically controllable pressure eld of heterogeneous MREs, was used to clarify the forming mechanism.

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“…Currently, MRFs are widely used in the automotive field for brakes [12] and clutches [13], in the biomedical field for prostheses [14] and for these applications there are already available constitutive models which are able to describe the field-dependent MRF characteristics (shear stress vs. shear rate) [15]. As for their applications within the manufacturing processes, they are used for finishing [16] and sheet metal forming operations [17,18]. However, there are still few studies in literature about the most effective way to characterise the MRFs when used for sheet metal forming applications: Wang et al [19] used a combination of extrusion tests and FEM simulations to characterize a kind of MRF, in order to apply the obtained characterization to the simulation of bulge tests using MRF as forming medium.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of the Rheological Behaviour of Magnetorheological Fluids Combining Bulge Tests and Inverse Analysis

Cusanno

Piccininni

Guglielmi

et al. 2022

KEM

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Magnetorheological Fluids (MRFs) are included in the so called “smart materials”: they are suspensions of magnetically responsive particles in a liquid carrier, whose rheological behaviour (e.g., its viscosity) can be changed quickly and reversibly if subjected to a magnetic field. Their application as forming medium in sheet metal forming processes is gaining interests in the recent years since the thickness and the strain distribution on the formed part can be affected by properly changing the properties of the MRF. In order to widely adopt MRFs in such processes, the evaluation of their rheological behaviour according to the applied magnetic field plays a key role. But there are still few works in the literature about the most effective way to characterise the MRFs to be used in sheet metal forming applications.In this work, the rheological behaviour of a MRF is carried out by means of an inverse analysis approach using data from bulge tests performed using an MRF as forming medium. Bulge tests were conducted on sheets having known properties using an equipment with a solenoid to generate the magnetic field, which was specifically designed and manufactured. Pressure rate and magnetic flux density were varied according to a Design of Experiments (DoE) while the strain experienced by the sheet material was acquired by means of a Digital Image Correlation (DIC) system in order to compare it with the numerical one. In particular, the fitting between numerical and experimental data was obtained by changing the MRF’s rheological properties using an inverse analysis technique. The proposed methodology allows to evaluate the MRF behaviour at different levels of both magnetic field and pressure rate, which are determinant for the FE simulation of sheet metal forming processes.

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Mechanism of magnetic field condition on deformation behavior of sheet metal using a property-adjustable flexible-die

Cited by 9 publications

References 22 publications

A novel process of sheet metal inverse bulging pre-deformation for deep drawing forming using magnetorheological fluid as flexible media

A novel process of sheet metal inverse bulging pre-deformation for deep drawing forming using magnetorheological fluid as flexible media

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

Evaluation of the Rheological Behaviour of Magnetorheological Fluids Combining Bulge Tests and Inverse Analysis

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