Abstract
This paper presents the design of cold-formed rounded connections between a tube and a connecting block and the analysis of test results that were carried out with six fabricated samples. The joints manufactured on a specially designed prototype station were made by forming tools that were adjusted to connecting elements regarding the diameter and the shape. All of the samples prepared for this study were of the same diameters relating to the diameter of a hole in a connecting block and the outer diameter of a pipe flange. However, they were different concerning the height of the connecting block flange. The article presents features of joints that were manufactured with a designed forming tool on the prototype station. The achieved connections were examined in destructive testing (Micrography, Tensile Strength Test) and in non-destructive testing (Leakage Test). The research project aims were to state the differences in energy consumption of made connections and extend the concept of cold-formed rounded connections. Furthermore, this article presents the effects of FEA simulation of the cold-formed joint based on the results of destructive and non-destructive tests.
Highlights
Connections that formed on account of material deformation in joining elements can be often found in production of components in different industries, i.e., in the case of the automotive industry, they can be found in components of fuel pumps, in all kinds of coolers and condensers, or even in large components, such as engine blocks
The pipe end forming process studied in the article assumes the use of clamps to hold the formed material and the forming tools in order to significantly change the shape of pipe end
The first test was of based on a micrograph photo of the formed joint cross-section, us to analyze the process forming the joint and interference between the materialswhich of theenabled connection us to analyze the process of forming the joint and interference between the materials of the connection block flange and the pipe flange
Summary
Connections that formed on account of material deformation in joining elements can be often found in production of components in different industries, i.e., in the case of the automotive industry, they can be found in components of fuel pumps, in all kinds of coolers and condensers, or even in large components, such as engine blocks. The pipe end forming process studied in the article assumes the use of clamps to hold the formed material and the forming tools in order to significantly change the shape of pipe end. In such operations, a pipe end usually needs to be adjusted to the other element. Regardless of the final application, each formed joint needs to meet certain requirements
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