Experimental Approach to Predict the Forming Limit in Aluminum Alloy Tubes with Electromagnetic and Roll Forming Process

Abstract

Tube compression forming is defined as the ability of a metal to deform plastically or change the shape of the tube into a new desirable shape without failure. To control the operation of tube compression forming without failure, a FLD (formability limit diagram) is invariably used to determine the acceptable range of critical deformation. Every tube has its own limit of ductility, which determines its formability and strain state. FLD can be evaluated by using theoretical, experimental and simulation approaches. In this paper, the experimental evaluation of the forming limit for an aluminum alloy tube in electromagnetic forming under various energy levels, and roll forming under different pressures, are discussed. This method allows the determination of the forming-limit, and the strain and stress diagrams. Further this study makes an analysis of the influence of the material behaviour parameters under various energy and pressure levels. It is found that the electromagnetic compression forming processed aluminum alloy tubes have good formability behaviour compared with roll compression forming.