Ce Liang, Binglong Gao, Songyue Yang, Yu Wen, Yi Li
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Research on magnetorheological elastomer assisted flexible multi-point stretch-bending technology
Creasing defects in aluminum profiles post-forming significantly hinder their utilization. This study aimed to mitigate these defects by investigating the causes and mitigating strategies for two types of creases in aluminum profiles formed via flexible stretch bending with roller-type multi-point dies (FSBRD). To achieve dynamic control over the mold surface, magnetorheological elastomers (MREs) were employed to harness their magnetorheological effect, enabling adjustable mold hardness. The adjustable hardness of the mold, enabled by MREs, was investigated under varying magnetic inductions to form T-shaped profiles. The results quantitatively demonstrate that the addition of MREs significantly reduces crease defects, with a minimum value of thick direction strain not exceeding -0.1, and improves moulding quality. Specifically, at a profile thickness of 10mm, an optimal magnetic induction of 200mT minimized crease depth, while for a 66mm thickness, 400mT was most effective. It was also found that increasing the coefficient of friction between the MRE and the contour resulted in a decrease in crease depth and a decrease followed by an increase in crease height. Experimental validation confirmed the simulation accuracy, with thickness trends of the experimentally formed profiles closely matching the simulated ones. The study concludes that the FSBRD-M process is effective in controlling creases and expands the application of MREs in forming technology.
期刊介绍:
The Journal publishes and disseminates original research in the field of material forming. The research should constitute major achievements in the understanding, modeling or simulation of material forming processes. In this respect ‘forming’ implies a deliberate deformation of material.
The journal establishes a platform of communication between engineers and scientists, covering all forming processes, including sheet forming, bulk forming, powder forming, forming in near-melt conditions (injection moulding, thixoforming, film blowing etc.), micro-forming, hydro-forming, thermo-forming, incremental forming etc. Other manufacturing technologies like machining and cutting can be included if the focus of the work is on plastic deformations.
All materials (metals, ceramics, polymers, composites, glass, wood, fibre reinforced materials, materials in food processing, biomaterials, nano-materials, shape memory alloys etc.) and approaches (micro-macro modelling, thermo-mechanical modelling, numerical simulation including new and advanced numerical strategies, experimental analysis, inverse analysis, model identification, optimization, design and control of forming tools and machines, wear and friction, mechanical behavior and formability of materials etc.) are concerned.