FORMING PROCESSES USING MAGNETORHEOLOGICAL FLUID TOOLING

1 . A method for forming a part with a tooling assembly comprising:

forming a magnetorheological fluid bladder located within the tooling assembly into a desired shape;

placing the part in the tooling assembly; and

forming the part with the tooling assembly by applying pressure until the part obtains the desired shape from the magnetorheological fluid bladder.

2 . The method of claim 1 , wherein forming the magnetorheological fluid bladder further comprises:

placing a template in the tooling assembly;

applying pressure to the template to form the magnetorheological fluid bladder into the desired shape; and

applying a stimulus to the magnetorheological fluid bladder to activate magnetorheological fluid located within the magnetorheological fluid bladder to maintain the desired shape.

3 . The method of claim 2 , further comprising removing the stimulus to inactivate the magnetorheological fluid located within the magnetorheological fluid bladder.

4 . The method of claim 2 , wherein applying the stimulus further comprises applying different amounts of stimulus to different areas of the magnetorheological fluid to provide different stiffnesses in the respective different areas of the magnetorheological fluid bladder.

5 . The method of claim 2 , further comprising positioning a magnetic coil proximate to the magnetorheological fluid bladder in a position to apply the stimulus in a desired direction toward the magnetorheological fluid.

6 . The method of claim 1 , further comprising repeating the placing of the part in the tooling assembly and forming the part.

7 . The method of claim 1 , wherein forming the part further comprises varying a stiffness of the magnetorheological fluid in at least a first location to assist in controlling flow of the material during forming of the part.

8 . A method of forming a magnetorheological fluid bladder for use with a tooling assembly comprising:

placing a template in a cavity defined by the tooling assembly, wherein the magnetorheological fluid bladder is located within the cavity and is filled with a magnetorheological fluid in an inactivated state;

applying pressure with the tooling assembly to form the magnetorheological fluid bladder into the desired shape of the template; and

applying a stimulus to the magnetorheological fluid bladder to activate the magnetorheological fluid located within the magnetorheological fluid bladder to maintain the desired shape.

9 . The method of claim 8 , wherein applying the stimulus further comprises applying different amounts of stimulus to different areas of the magnetorheological fluid to provide different stiffnesses in the respective different areas of the magnetorheological fluid bladder.

10 . The method of claim 9 , wherein applying the different amounts of stimulus further comprises applying at least a first stimulus with a first magnetic coil and applying a second stimulus with a second magnetic coil.

11 . The method of claim 8 , further comprising positioning a magnetic coil proximate to the magnetorheological fluid bladder in a position to apply the stimulus in a desired direction toward the magnetorheological fluid.

12 . The method of claim 8 , further comprising removing the stimulus to inactivate the magnetorheological fluid located within the magnetorheological fluid bladder.

13 . The method of claim 8 , further comprising repeating the steps of placing a template in the cavity of the tooling assembly, applying pressure with the tooling assembly, and applying a stimulus to the magnetorheological fluid bladder with another template having a different desired shape than the first template.

14 . A tooling assembly for forming a part comprising:

a die at least partially forming a die cavity;

a punch located proximate to the die and moveable toward the die cavity; and

a magnetorheological fluid bladder located within the die cavity operable to be formed into a desired shape for forming the part.

15 . The tooling assembly of claim 14 , wherein a magnetorheological fluid is located within the magnetorheological fluid bladder, wherein the magnetorheological fluid is operable to have an increased stiffness when a stimulus is applied thereto, and wherein the increased stiffness is operable to maintain the magnetorheological fluid in a shape while the stimulus is applied.

16 . The tooling assembly of claim 14 , further comprising at least one magnetic coil located proximate to the magnetorheological fluid bladder to apply a stimulus to the magnetorheological fluid.