Experimental study and analysis of electromagnetic and roll forming on AA6101 tubes

Abstract

The forming is a process used to modify sheet metal or tubular newlinework piece into desired object by application of force, without removing any newlinematerial. Forming is done with heat and pressure or with mechanical force, or newlinewith both. To overcome the number of long-standing problems in newlineconventional forming technique such as difficulty in fabricating light weight newlinecomponents, formability, mechanical properties, distortion due to elastic newlinestrains, expensive inflexible forming technique, production rate etc., an newlinealternate approach of high energy rate forming methods are necessary. High newlineenergy rate forming (HERF) methods successfully address problems faced in newlineconventional forming techniques. HERF can be effectively used for forming newlinemetals with low formability like aluminum alloys and high strength steel. They can be instrumental in manufacturing of lighter vehicles with higher newlinefuel efficiency. newlineElectromagnetic forming (EMF) is one among the HERF method newlinethat is gaining wide acceptance due to its advantages and scope for newlinecommercialization. Electromagnetic forming (EMF) is a non conventional newlinemetal working process that relies on the use of electromagnetic forces to newlinedeform metallic work pieces with high electrical conductivity such as copper and aluminum alloys at high speeds. Tubular or structural components can be newlinecompressed by means of compression coils or expanded by means of newlineexpansion coils while the flat sheet metal can be deformed by flat coils. Roll newlineforming, an alternate forming technique is successfully used for the materials newlinethat are difficult to form by conventional methods, due spring back effect newlinewhile this process achieves better plastic deformation without spring back. In newlinethis process, sheet metal, tubes and strips are fed between successive pairs of newlinerolls, that are progressively bent and formed, until obtaining the desired shape and cross section. newline