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Mechanism of pre-deformation effect on sheet deep-drawing forming under magnetic field condition using a magnetorheological fluid (MRF) medium

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Abstract

Due to the poor plasticity of an aluminum alloy at room temperature, it is difficult to form thin-walled and complex curved parts. This paper proposes a composite method of inverse bulge pre-deformation deep-drawing based on intelligent magnetorheological (MR) fluid material. The experiments and FEM modeling of cylindrical parts with drawing ratios of K1 = 2.125 and K2=2.25 were carried out under different forming conditions. The effect of soft mold medium on the drawing forming of cylindrical parts was studied. The research results show that the uniformity of the wall thickness of the parts is enhanced after using the soft mold medium. When the inverse bulge height is about 9mm and 5mm, the wall thickness variance of the cylindrical part is 0.0023 and 0.0025, respectively, which is reduced by 86.31% and 82.8%, respectively. In the pre-deformation stage, as the height of the inverse bulge is increased, the maximum equivalent stress moves from the fillet area of the blank holder to the outer surface of the highest point of the bulging area. Taking a drawing ratio of K1 = 2.125 as an example, the circumferential compressive stress in the flange area decreases and is distributed uniformly under the back pressure and soft draw beads; the radial stress gradient and equivalent stress gradient at the fillet of die are reduced. For cylindrical parts with drawing ratios of K1 = 2.125 and K2 = 2.25, when the inverse bulge height is 9mm and 5mm, the forming effect of the part is the best.

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The data obtained in the framework of this study are available to the journal upon request.

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Funding

This paper was financially supported by the Key Laboratory of Micro-systems and Micro-structures Manufacturing (Harbin Institute of Technology), Ministry of Education, and the Fundamental Research Foundation for Universities of Heilongjiang Province (LGYC2018JQ011).

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Authors and Affiliations

  1. School of Materials Science and Chemical Engineering, Harbin University of Science and Technology, Harbin, 150040, China

    Yuan Yuan Mu, Feng Li, Chao Li & Yun Qi Zang

  2. Key Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin, 150080, People’s Republic of China

    Feng Li

  3. Key Laboratory of Micro-systems and Micro-structures Manufacturing, Ministry of Education, Harbin Institute of Technology, Harbin, 150080, China

    Jie Xu

Authors
  1. Yuan Yuan Mu
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  2. Feng Li
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  3. Chao Li
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  4. Yun Qi Zang
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  5. Jie Xu
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Contributions

Yuan Yuan Mu: Conceptualization, Methodology, Writing- Original draft preparation, Experimental scheme design. Feng Li: Writing- Reviewing and Editing. Chao Li: Experiment. Yun Qi Zang: Verification. Validation. Xu Jie: Supervision.

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Correspondence to Feng Li.

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Mu, Y.Y., Li, F., Li, C. et al. Mechanism of pre-deformation effect on sheet deep-drawing forming under magnetic field condition using a magnetorheological fluid (MRF) medium. Int J Adv Manuf Technol 116, 863–875 (2021). https://doi.org/10.1007/s00170-021-07481-w

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  • DOI: https://doi.org/10.1007/s00170-021-07481-w

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