Lehrstuhl für Fertigungstechnologie, Universität Erlangen-Nürnberg

Hydroforming of metal sheets using magnetorheological fluids as forming and sealing medium

Datum: 18.12.2013



  • Prof. Dr.-Ing. habil. M. Merklein
  • Prof. Dr.-Ing. habil. K. Willner

The scope of this thesis was to enhance theprocess window of hydroforming processesfor single metal sheets. This was achievedby using a magnetorheological fluid andsimultaneously applying an external magneticfield. The mentioned suspension therebyacts as forming and sealing medium atthe same time.The shift of the sealing limit, which is animportant process boundary for blank hydroformingprocesses, is due to the activationof the magnetorheological effect by theexternal magnetic field. This effect leads toa higher process robustness and enhancedforming possibilities. To characterize thefluid behaviour it was necessary to build upa qualified tooling and systems technology.The development of the experimental setupsand the comparison between experimentaland numerical results additionally requiredthe simulation of the magnetic fields, theleakage and the forming operation itself.Finally the essential findings were concludedin a methodology for sheet metal hydroformingprocesses with magnetorheologicalfluid as active fluid medium.