Analysis: The Process of Forming A Flat Surface from Copper Pipe using the Warm Forming Method

Abstract The formation of copper pipes is a crucial process in various industries, especially in the production of electrical system components. However, the formation process at room temperature or conventionally cold temperatures often faces significant challenges, such as wrinkles, cracks due to excessive thinning, and high springback. As a result, large forming forces are required, which can cause dimensional and surface defects that affect product function. Therefore, this study aims to analyze the formation of copper pipes with a warm forming process using forming tools in the form of punches and dies that focus on the influence of temperature and tool design on the quality of the final product. Applied methods include laboratory experiments and numerical simulations to evaluate optimal process parameters. The specimen used is an electrical component that is a cable lug Series 400. The specimens were formed at temperatures of 120°C, 250°C, and 400°C by preheating using an iron pipe housing conductor. While at a temperature of 450°C and 530°C, preheating with graphite conductors. The results showed that the surface of the cable lug is best produced from a flat hemming process with a material temperature of 250°C and 400°C. The optimal distance between punch and dies for the formation of flat surfaces is 6.1 mm. The conclusion of this study confirms that the selection of the right temperature and tool design is important to achieve the desired results in the warm forming process.