Journal of Jilin University(Engineering and Technology Edition) ›› 2025, Vol. 55 ›› Issue (11): 3564-3574.doi: 10.13229/j.cnki.jdxbgxb.20240257

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Roll bending forming of commercial vehicle bumper beams based on magnetorheological elastomers

Yi LI1(),Wei-peng HUANG1,Min CHENG2(),Ji-cai LIANG1   

  1. 1.College of Materials Science and Engineering，Jilin University，Changchun 130022，China
    2.School of Mechanical and Aerospace Engineering，Jilin University，Changchun 130022，China
  • Received:2024-03-13 Online:2025-11-01 Published:2026-02-03
  • Contact: Min CHENG E-mail:henrylee@jlu.edu.cn;792493209@qq.com

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Abstract:

This paper adopts the roll bending forming process to bend profiles with a "日" shaped cross-section into commercial vehicle bumper beams. During the actual processing and forming process， profiles often exhibit forming defects such as wrinkling and cross-sectional distortion. To address this， an in-depth numerical simulation of the coreless mandrel-supported profile forming process was conducted using ABAQUS finite element software， aimed at analyzing the mechanism of defect formation. Based on this analysis， a new type of mandrel—a novel magnetically controlled mandrel—was designed and studied. This mandrel not only exhibits excellent forming quality in bending "日" shaped structural profiles， but also significantly improves the performance of the traditional mandrel forming processes. Moreover， by altering forming parameters such as the bending radius and die gap， the paper explored the limits of process parameters for profile bending， seeking to find the extreme process parameters while ensuring accuracy.

Key words: commercial vehicle bumper beam, magnetorheological elastomer, mechanical testing, novel magnetically controlled mandrel

CLC Number: 

  • TG386

Table 1

Mechanical properties of high-strength steel B700L"

杨氏模量/GPa密度/（kg·m-3）泊松比
2167 8500.22

Fig.1

Schematic diagram of finite element model of the profile"

Table 2

Formulations of MREs composites"

样 品MRE-60CIP
总共381.5
NR70
BR30
羰基铁粉230
硅炭黑30
少层石墨烯3
氧化锌5
硬脂酸1
防氧化剂40202
防氧化剂RD2
促进剂CZ2
增塑剂古马龙7.5
硫磺2

Fig.2

Self-developed magnetic field generation device"

Fig.3

Schematic diagram of bending forming"

Fig.4

Sectional deformation diagram of the profile before and after bending"

Fig.5

Finite element simulation of the RDB process without a mandrel"

Fig.6

Scanning electron microscope images of MRE-0CIP and MRE-60CIP"

Fig.7

Mechanical properties of MRE-60CIP"

Table 3

Mechanical properties of MREs with different CIPs content"

样品

MRE-

0 CIP

MRE-

30 CIP

MRE-

60 CIP

拉伸强度16.1817.7819.46
100%应变下的应力0.781.562.32
300%应变下的应力1.484.496.23
压缩模量4.044.976.59

Table 4

Magneto-rheological effect of MREs with different CIPs content"

样品G0/MPaGmax/MPa(Gmax-G0)/G0/%
MRE-0CIP0.9750.9790.410
MRE-30CIP1.7111.96815.001
MRE-60CIP1.8162.22522.501

Fig.8

Finite element simulation of the RDB process under magnetic-controlled mandrel"

Fig.9

Mises stress cloud image and wall thickness cloud image under different bending radius"

Fig.10

Different bending radius"

Fig.11

Cloud image of mises stress distribution under different clearance parameters"

Fig.12

Cloud image of transverse displacement distribution under different clearance parameters"

Fig.13

Influence curve of die gap variation on thickness increase rate"

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