Abstract
This paper is built upon the deformation-assisted joining of sheets to tubes, away from the tube ends, by means of a new process developed by the authors. The process is based on mechanical joining by means of form-fit joints that are obtained by annular squeezing (compression) of the sheet surfaces adjacent to the tubes. The concept is different from the fixing of sheets to tubes by applying direct loading on the tubes, as is currently done in existing deformation-assisted joining solutions. The process is carried out at room temperature and its development is a contribution towards ecological and sustainable manufacturing practices due to savings in material and energy consumption and to easier end-of-life disassembly and recycling when compared to alternative processes based on fastening, riveting, welding and adhesive bonding. The paper is focused on the main process parameters and special emphasis is put on sheet thickness, squeezing depth, and cross-section recess length of the punches. The presentation is supported by experimentation and finite element modelling, and results show that appropriate process parameters should ensure a compromise between the geometry of the mechanical interlocking and the pull-out strength of the new sheet–tube connections.
Highlights
In recent years, there has been a growing utilization of deformation-assisted joining processes driven by an increasing demand of assembling lightweight components
Hydraulic, and magnetic loading, such as clinching [1,2], self-pierce riveting [3], sheet-bulk compression [4], hydraulic forming [5], and electro-magnetic forming [6]; (ii) Based on solid-state welding, such as friction stir welding [7], friction spot welding [8] and explosive welding [9]; (iii) Based on fusion welding combined with plastic deformation, such as resistance spot and projection welding [10] and weldbonding [11]
Some of the above-mentioned processes have been extensively investigated for joining sheets and tubes made from similar or dissimilar materials
Summary
There has been a growing utilization of deformation-assisted joining processes driven by an increasing demand of assembling lightweight components. Deformation-assisted joining processes are classified into three distinct groups according to their operating principles: (i). (ii) Based on solid-state welding, such as friction stir welding [7], friction spot welding [8] and explosive welding [9];. Some of the above-mentioned processes have been extensively investigated for joining sheets and tubes made from similar or dissimilar materials. The state-of-the-art reviews by Mori et al [12] and Groche et al [13] provide detailed information on the most significant developments and applications of deformation-assisted joining processes to connect sheets and tubes.
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