Electromagnetic forming is an inevitable and tedious task even in modern engineering practices. Aluminum alloys are widely used in industrial structures and components, where light-weight and good corrosion resistance is required. This paper explains the Response Surface Methodology (RSM)-based design of experiment (DoE) for the optimization of electromagnetic forming of AA6101 tubes. The forming experiments were conducted based on the full factorial DoE, by varying the energy level, air gap and number of turns as the forming parameters, against the responses of force, deformation and time. The combined effects of the energy level, air gap and number of turns on the performance measures of force, deformation and time were investigated by the analysis of variance. The optimization results were plotted using the RSM, and the optimal forming parameters were obtained. The validation experiments were conducted using the optimum forming considerations and the results were compared.

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