Optimization of AL6061-T6 Tube End Forming Process Using Response Surface Method

Tube end closing is a metal forming process that replaces welding processes while closing tubes ends. It depends on deforming a rotating tube using a roller, and therefore, it is also called tube end spinning. The process involves many parameters like contact depth, roller inclination angle, roller diameter, mandrel curvature, and tube rotational speed. This study develops a finite element model (FE-model) for this process and validates it through experimental results. The numerical and experimental results have shown minor deviation of 1.87%. The FE-model is then employed to carry out a statistical analysis based on the response surface method (RSM). The analysis of variance (ANOVA) and regression analysis have proved the accuracy of the obtained mathematical model. The contact depth has proved to have the most significant effect in the process responses, while the roller diameter has the least effect. Finally, an optimization analysis is carried out to select the finest conditions for the process.