Experimental and Numerical Investigation of AA6061 Tube Flowformability

Abstract:

This study introduces a novel flowformability test aimed at replicating the complex loading conditions of industrial flowforming processes—alternating stress triaxiality, large plastic strains, and high strain rates. A novel Conical Flowformability Test (CFT) configuration was selected for experimental validation due to its ability to achieve a high theoretical thickness reduction while respecting machine constraints. Experiments conducted on AA6061 in O-temper and W+3h states demonstrated substantial thickness reductions. Comparison between the numerical simulations using the software FORGE® and the experimental results is satisfactory despite certain unquantifiable experimental defects such as fish scales and material build-up. The current study paves way to establish a robust framework for assessing material flowformability and damage evolution under realistic process conditions.

• Periodical: Solid State Phenomena (Volume 389)
• Pages: 207-215
• DOI: https://doi.org/10.4028/p-kh92Rm
• Online since: April 2026
• Authors: Katia Mocellin*, Nagasai Meghana Rani Kauta, Pierre Olivier Bouchard
• Keywords: AA6061, Finite Element Simulation, Flow Forming, Tube Flowformability

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