Recent research and advances in sheet/tube magnetorheological controllable flexible-die forming process: a review

Due to its excellent filling capacity, good forming accuracy, and low die manufacturing costs, the sheet/tube flexible-die forming process has become an important supplement to traditional rigid die forming processes, widely used in the multi-variety, small and medium-sized batch manufacturing of complex thin-walled components in high-end manufacturing fields, such as aviation, aerospace, and automobiles. To match the deformation characteristics of different types of sheet/tube components, flexible mediums with different physical and mechanical properties were used as pressure-carrying dies and exhibited their respective advantages. Among them, what is remarkable is that magnetorheological materials, a type of intelligent material, have been introduced into flexible-die forming and develop into sheet/tube magnetorheological controllable flexible-die forming process. Real-time control of magnetorheological flexible-die performance can be achieved through an external adjustable magnetic field, improving the process control flexibility of the forming process and enhancing the forming performance and quality of parts. This article reviews the latest research progress in the sheet/tube magnetorheological controllable flexible-die forming process in recent years, and elaborates on the forming principles, control patterns, forming methods, and forming mechanisms. Finally, the future development direction of the magnetorheological controllable flexible-die pressure forming process for sheet/tube materials is prospected.