Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Sheet metal hydroforming using magnetorheological fluid as forming and sealing fluid

Project Status: finished


The sealing limit is one important limitation of the process window of sheet metal hydroforming. Necessary calibration pressure cannot be reached because of leakages if the blankholder force is too low. Avoiding these leakages by using special active fluid media like magnetorheological fluids can strongly increase the robustness of the forming process. The viscosity of these fluids increases with the applied magnetic field density, which leads to a decrease of leakage volume and an increase of the cavity pressure at the same time. The aim of this research project is to investigate wether the mentioned fluids can be used as a combined forming and sealing medium for forming processes and wether the selective application of magnetic fields in the flange area leads to a decrease of leakage rates. Thus the uncontrolled occurrence of leakages in hydroforming could be prevented.


Detailed view of the experimental setup and demonstrator parts formed at different cavity pressures

Research Groups



    • Degner, J.; Herrmann, J.; Junker, F.; Berendt, E.; Merklein, M.:
      Leichtbauwerkstoffe für den modernen Automobilbau.
      Zeitschrift Konstruktion 3(2018), pp. 50-54


    • Rösel, S.; Merklein, M.; Grüner, M.:
      Analytical and numerical approaches to predict the flow characteristics of a magnetorheological fluid in rotational symmetric cross sections.
      Key Engineering Materials 504-506(2012), pp. 399-404


    • Rösel, S.; Merklein, M.:
      Flow behaviour of magnetorheological fluids, considering the challenge of sealing in blank hydroforming in the flange area with rectangular leakage area cross-sections.
      Key Engineering Materials 473(2011), pp. 121-129

    • Rösel, S.; Merklein, M.:
      Enhancing Forming Limits by Using a Magnetorheological Fluid as Active Fluid Medium for Hydroforming.
      In: Gerhard Hirt, A. Erman Tekkaya (Edtr.): Steel research international: Special Edition: 10th International Conference on Technology of Plasticity, Wiley-VCH Verlag GmbH&Co. KGaA., 2011, pp. 453-458


    • Rösel, S.; Merklein, M.:
      Characterization of a Magnetorheological Fluid with Respect to its Suitability for Hydroforming.
      International Journal of Material Forming 3(2010), pp. 283-286

    • Rösel, S.; Merklein, M.:
      Characterization of a magnetorheological fluid and simulative design of a magnetic field with respect to its suitability for hydroforming.
      In: Warsaw University of Technology, Faculty of Production Engineering (Edtr.): Proceedings of the 5th International Conference on ADVANCES IN PRODUCTION ENGINEERING, Publishing and Printing House of the Institute for Sustainable Technologies, 2010, pp. 409-417

    Letztes Update: 17.07.2012