Investigations on deformation behavior of square box deep drawing using a magnetorheological fluid (MRF)

Abstract

The magnetic medium-assisted sheet forming is a new flexible die forming, which can give full play to comprehensive advantages and characteristics of common force-transmitting mediums, such as liquid, semi-solid, and solid mediums, and play the role of directional, quantitative, and controllable loading effect. This paper attempts to use this medium for the deep drawing process experiment of auxiliary square box; a special tooling structure is developed. Results show that the wall thickness of the square box diagonal section, from the bottom center to the flange, reduces first and then increases; the largest thinning section is located at the punch fillet area. With the increase of current intensity, the thinning amount of square box reduces and the overall deformation uniformity is improved. The springback at 6A is only 0.52 mm, and the forming limit compared with that at 0A is increased by 21.74% at 6A. Meanwhile, the attaching capability has been greatly improved, the quality and dimensional precision of square box is also greatly improved. The experimental investigations provide a scientific basis for the development of flexible die forming process in complex special-shaped sheet metal parts.