Based on the desperate demand for the complicated hollow part with large diameter ratio in aerospace

a novel tube forming technology based on magnetorheological elastomer (MRE) is proposed. The paper systematically introduced the preparation of MRE

the theory of compression mechanical property of MRE and experimental testing

the development of forming process and the design of tools

construction of finite element (FE) model and FE simulation

the application of the technology in forming complicated tube. The obtained results show that the novel technology can realize the differential loading of the forming pressure to promote the flow of material and effectively resolve the sealing problem during tube hydroforming by applying external magnetic field. In the future

this novel technology may provide forward looking technical support to the integrated precise forming of complicated hollow part with large diameter ratio.