Numerical Investigation on Effect of Tool Geometry and Process Parameters on Forces During Backward Flow Forming Process

Flow forming is a developed form of metal spinning, which is the oldest method of forming. It is a seamless and cold manufacturing process that improves material properties such as yield strength and fatigue life. Commonly, there are three forces that come across the process, i.e., radial, axial, and circumferential forces. For tool design of various materials and geometry, the knowledge of forces is vital. The process of determining the forces is challenging during machine operations. Thus, to measure forces during the process a simulation model is developed. Taguchi-based analysis has been carried out to find the influence of tool geometry and process parameters (attack angle, rotational speed, thickness reduction, wall thickness, and feed rate) on radial force, axial force, and circumferential force. Each parameter is varied for four levels and the L16 orthogonal array is used. The ANOVA tool has been used to summarize the contribution of each variable. The material used was AA6063 because it is lightweight, recyclable, corrosion-resistance, and cost-effective. The results show that the value of radial force is highest followed by axial and circumferential forces. The thickness reduction is the significant parameter contributing more to radial force, axial force, and circumferential force compared to other parameters.