Abstract
Flow forming is a modern, chipless metal forming process that is employed for the production of thin-walled seamless tubes. Experiments are conducted on AA6082 alloy pre-forms to flow form into thin-walled tubes on a CNC flow-forming machine with a single roller. Design of experiments is used to predict the surface roughness of flow-formed tubes. The process parameters selected for this study are the roller axial feed, mandrel speed, and roller radius. A standard response surface methodology (RSM) called the Box-Behnken design is used to perform the experimental runs. The regression model developed by RSM successfully predicts the surface roughness of AA6082 flow-formed tubes within the range of the selected process parameters.
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