Investigation of the reshaping process by hydroforming using magnetorheological fluids

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Investigation of the reshaping process by hydroforming using magnetorheological fluids

PICCININNI Antonio, CUSANNO Angela, INGARAO Giuseppe, PALUMBO Gianfranco, FRATINI Livan

Abstract. The reshaping of End-of-Life (EoL) components is considered a promising approach to put in practice one of the virtuous strategies of the Circular Economy. The heterogeneity in a EoL part, the alternation of deformed/undeformed regions resulting from the manufacturing process, may hinder an effective reshaping into a brand new geometry. Therefore, the proper selection among the sheet metal forming processes to overcome such a limitation is of utmost importance. The present work, based on a full numerical approach, investigates the reshaping process of a disc-shaped EoL by hydroforming using a Magneto Rheological Fluid (MRF) as the forming medium. The basic idea is to combine the advantages coming from the flexibility of the hydroforming process with those from the MRF whose behavior (i.e. its viscosity affecting the shear stresses at the contact with the blank) can be tailored by adjusting the applied magnetic field. The reshaping approach is investigated according to two separate routes, differentiated by a different target geometry. A factorial plan of numerical simulations allowed to investigate the effect of the MRF behaviour as well as the geometry of the EoL component on the quality of the reshaped part, expressed in terms of accuracy in the final shape and thickness distribution.

Keywords
Aluminium, Reshaping, Hydroforming, Magnetorheological Fluids

Published online 4/24/2024, 11 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: PICCININNI Antonio, CUSANNO Angela, INGARAO Giuseppe, PALUMBO Gianfranco, FRATINI Livan, Investigation of the reshaping process by hydroforming using magnetorheological fluids, Materials Research Proceedings, Vol. 41, pp 2839-2849, 2024

DOI: https://doi.org/10.21741/9781644903131-311

The article was published as article 311 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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