Numerical and experimental investigation of dimensional accuracy in incremental forming of AA6063 tubes

Abstract

In the incremental tube forming process, a tool forms a desired shape on a tube by applying local force on a predetermined path. A rotating tool produces a symmetric bulge in the central region of AA6063 aluminum tubes. The forming process has been carried out in several steps and the final profiles of the components have been studied. The process is repeated to achieve the desired bulge height. The effects of process parameters are investigated on the spring-back and final tube length. The process is simulated using Abacus and the numerical results have shown good agreement with the experiments. The results show that the reduction of the axial pitch and the forming depth increases the plastic strain resulting in less spring-back. Tool velocity does not have a significant effect on the final diameter. By choosing the least forming depth and highest axial pitch, minimum change occurs along the tube.