DESIGN AND DEVELOPMENT OF
BLANKING DIE USING ELASTOMERS
GROUP MEMBERS:
NITISH KUMAR (18MMF0007)
ANJANA L (18MMF0002)
ANUSHA T (18MMF0037)
M.THANIGAI ARASU (18MMF0008)
Under the guidance of Prof.Pandivelan.C
Abstract— Magnetorheological (MR) elastomers have
attracted a significant amount of attention for their enormous
potential in engineering applications. Because they are a solid
counterpart to MR fluids, MR elastomers exhibit a unique field-
dependent material property when exposed to a magnetic field,
and they overcome major issues faced in magnetorheological
fluids, e.g. the deposition of iron particles, sealing problems and
environmental contamination. Such advantages offer great
potential for designing intelligent devices to be used in various
engineering fields, especially in fields that involve vibration
reduction and isolation. A comprehensive review has been
presented on MR elastomers , and modeling and analysis of the
mechanical behavior of both punch and die is presented.
Keywords: magnetorheological elastomer, punch, die,
mechanical analysis.
I. INTRODUCTION
Smart materials are materials with properties that can be
significantly altered in a controlled fashion by external
stimuli, such as stress, temperature, pH, moisture, electric or
magnetic fields. Common examples of smart materials are
memory shape alloys and piezoelectric materials.
Magnetorheological materials, similar in principle to
electrorheological materials, have their viscoelastic and
rheological properties altered in the presence of a magnetic
field. They exhibit a fast response to external stimuli, of the
order of milliseconds.
Magnetorheological Elastomers (MREs) belong to a class of
materials known as Smart Materials. An elastomer
comprising a matrix interspersed with micron sized
ferromagnetic particles is known as a Magnetorheological
Elastomer (MRE). The rheological properties of MREs (the
deformation and flow behaviour under stress) are altered by
the application of an external magnetic field. The
characteristic response will be influenced by many factors
including; the elastomer matrix, the size, distribution,
composition and percentage volume of the ferromagnetic
particles, and whether the ferromagnetic particles are
aligned in chains or randomly dispersed. It consist of
micronized magnetic particulates suspended on a non-
magnetic matrix . MR fluids are typical MR materials with
iron particles suspended in a liquid carrier fluid, the flow or
shear properties of which are controlled by the application
of a magnetic field . MR fluids have been widely used in
dampers for vibration control. Magneto rheological
elastomers (MREs) are the solid analog of MR fluids, where
the liquid is replaced by a rubber material. The obvious
advantage of using rubber matrix is that particles are not
able to settle with time and that there is no need to use
containers to keep the MR material in its place. Shear
modulus of an MRE can be changed reversibly by applying
an external magnetic field, which is called the magneto
rheological effect. The field induced dipole magnetic forces
between particulates are the origin of the MR effect.
II. LITERATURE REVIEW
Magnetorheological elastomers (MREs) are classified as a
new comparable smart material whose mechanical property
can be changed quickly and reversibly with the presentation
of the magnetic field [1,2]. These materials are composed of
magnetizable particle that embedded in a low-permeability
matrix with additives [3,4,5]. The polymer matrix that
commonly used for MREs is synthetic or natural rubber
[5,6]. Meanwhile, the magnetization particle is widely
carbonyl iron [6,7]. MREs are the solid-state analogs of MR
fluids (MRFs) [1,4,7] because the matrix of MREs is solid
form as compared to MRFs using a carrier oil. Therefore,
MREs can avert shortcoming of MRFs in term of particle
sedimentation and seal issues while providing stability for
passive application [3,4,5].
There are numerous factors which can affect the manner in
which an MRE will behave; for example, the elastomer
matrix will have its own material properties of elastic
modulus, density, etc. Therefore, material selection for the
elastomer matrix is very important for the viscoelastic
behaviour of the MRE. And similarly the material selected When a magnetic field is applied, however, the microscopic
for the micron sized magnetisable particles will have its own particles align themselves along the lines of magnetic flux
affect on the overall MRE behaviour. It is assumed that the as shown in Figure 2
ferromagnetic particles are uniformly magnetized, which is
valid if the particles are small enough (≤1.5μm for iron).
Negligible anisotropy effects in the magnetisation is also
assumed, which is justified for iron and iron-cobalt alloys
(due to them being cubic crystalline ferromagnetic
materials. Very low eddy current loss and a low total core
loss (relative to laminated steel) are also properties of
MREs. [9] The maximum possible magnetic field induced
change in stress (and modulus) occurs when the aligned Figure:2
particles become magnetically saturated. This observation
supports the use of a particle material with high The field induced dipole magnetic forces between
magnetization saturation. Pure iron has the highest particulates are the origin of the MR effect.
saturation. Magnetisation of known elements, but some
alloys of iron and cobalt have even higher saturation
magnetisations. Research [8] has shown that uniaxial field
structured composites consisting of magnetic particles in an III. DESIGN AND ANALYSIS OF PUNCH AND DIE
elastomer (a basic MRE) exhibit a larger increase in
modulus than random particle distributions (such as an
EFC), the increase in modulus is most significant if the The design of the punch and die is shown in the Figure 3
applied stress is parallel to the particle alignment. Many and 4 as shown below.
other features of the particles such as their size/shape,
distribution in the matrix and percentage volume of the
ferromagnetic particles in the elastomer matrix can have
effects on the overall behaviour of the MRE.
In general, magnetic forces arise due to the movement of
electrical charge. This can occur in two ways; the movement
of electrons in an electric current, which results in what is
known as electromagnetism, or the quantum-mechanical
spin and orbital motion of electrons in an atom. The latter of
these is the fundamental force in “permanent” or “hard”
magnets. Hard magnets remain magnetised when removed
from a magnetic field, however “soft” magnets lose their
magnetisation immediately when removed from the field. If
a piece of iron, or other ferromagnetic material, in an
unmagnetised state is placed in a weak magnetic field a
magnetic moment is induced. Such a field may be produced
by wrapping a current carrying electric wire around the Figure:3 -Design of punch
sample or by placing it in the vicinity of a permanent
magnet. Hysteresis develops as the magnetic field increases.
The hysteresis loop from saturation is a characteristic of the
specimen. The induction hysteresis loop has a different
shape. The hysteresis properties of ferromagnets are largely
properties of arrangements of magnetic domains [10].

The magnetic particles, typically of micrometer or

nanometer scale spheres or ellipsoids, are suspended within
the carrier oil and distributed randomly in suspension under
normal circumstances as mentioned in Figure 1

Figure:1
Figure:4 - Design of die
Figure: 5- Assembly of punch and die
IV. STATIC ANALYSIS AND RESULTS
The static analysis of the assembly is done in Ansys 16.0
software and the total deformation is analyzed.
Figure:6- Total deformation of the die
V. CONCLUSION
A die for blanking using elastomers as material is designed
successfully. Also analysis and simulation were performed
for the die. The analysis results gave maximum and
minimum values of Deformation. These results show that
the die design is feasible for manufacturing.
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