Abstract
This paper reports fabrication of a high density cylindrical pin pattern on a medium gauge aluminum alloy plate with utilizing friction-stir forming (FSF) approach. The authors put the plate on the mold having 1mm diameter and 0.5mm deep holes at 1.5mm pitch on its top, and then conducted friction stirring. Each band width to which completely and incompletely formed pins belonged was evaluated with single-pass experiments. The extrusion of the material to the mold cavity seemed to be mostly limited under the area of the tool shoulder, and faster spindle speed, slower tool feed rate and larger tool shoulder extended the band of completely formed pins. Height accuracy of completely formed pins was within ±0.013mm, which was remarkably accurate for a plastic forming.
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