Study on deep drawing of 304 stainless steel rectangular case with magnetic medium

A rectangular case is a typical structure of fairing whose hollow-shell geometric characteristics cause its deformation uniformity and forming quality to be difficult to control. Magnetorheological fluid (MRF) is a new smart force-transmitting medium whose state and performance can be controlled by magnetic field activation to achieve instantaneous and reversible changes. Herein, MRF was applied as a force-transmitting medium for the deep drawing process of a rectangular case. The greatest wall thickness reduction was located at the punch fillet area. As the current intensity increased from 0 to 3 A, the maximum thinning rate decreased from 29.6–20.1% and the global deformation uniformity of each area improved significantly. Meanwhile, the springback was greatly reduced, and the forming limit and forming quality were improved. These results show that MRF as a new type of force-transmitting media enriches the existing flexible die-forming system and opens up new possibilities.