Effect of Forming Temperature on Linear Roll Forming of 6011 Aluminum Sheets: An Analysis Based on Experimental Design

This study analyzed the effect of forming temperature on the roller hemming process of AA6011-T4 aluminum alloy sheets, using a 2K factorial design to also evaluate the influence of roller diameter and flange height. A total of 24 experimental tests were conducted, varying the forming temperature (23 °C and 50 °C), roller diameter (22 mm and 50 mm), and flange height (7 mm and 10 mm). The hemming process was performed using a six-axis industrial robot (FANUC 2000i, Fanuc Corporation, Oshino, Japan ) with roller tooling mounted o n a support fixture. The height of the flanged profile was measured using a coordinate measuring machine. ANOVA results, processed with MINITAB 18, showed that forming temperature, roller diameter, and flange height all have a statistically significant effect on the final profile height. No significant interactions were found among the factors, indicating their effects are independent. The most favorable configuration for maximizing profile height was the combination of the largest roller diameter and the highest flange height, under cold forming conditions. Additionally, a significant difference was observed between cold and warm forming processes in terms of the resulting profile height, highlighting the relevance of temperature control in the roller hemming of AA6011-T4 aluminum alloy.