Experimental study on warm incremental tube forming of AA6063 aluminum tubes

Document Type: Original Article


1 Department of Mechanical Engineering, Kar higher Education Institute, Qazvin, Iran

2 Mechanical Engineering Department, Faculty of Engineering, University of Birjand, Birjand, Iran

3 Department of Mechanical Engineering, Faculty of Enghelab-e Eslami, Tehran Branch, Technical and Vocational University (TVU), Tehran, Iran


Effect of temperature on formability of AA6063 aluminum tubes in incremental forming process. Experiments are performed on AA6063 aluminum tubes. A spirally moving tool incrementally expands the tube wall. The tube is clamped from both ends while the deformation zone is not in contact with the die. The forming continues to achieve maximum expansion until rupture. A circumferential heating system is used to heat the tube due to the low formability of aluminum alloys at ambient temperature. The temperatures of 100, 200 and 300°C are tested. The effects of process parameters including temperature, radial feed, axial feed and tool linear velocity are investigated in order to obtain the highest formability and surface quality. The results show that with a temperature rise from 100°C to 300°C, the expansion ratio increases from 28% to 34%. Axial feeding and temperature are the most effective parameters on the surface roughness and bulge diameter, respectively.