Abstract
The electrical, power, and automotive industries use copper-steel (Cu-SS), a peculiar material combination, in various applications. The current work deals with electromagnetically crimped threaded surfaced Cu-SS tube-to-tube (EMCT3) joints, as the deformation behavior of the joints cannot be predicted or examined using the FEM methods previously presented. Therefore, the present work develops a non-coupled multi-step FEM model for analyzing the deformation during EMCT3 joining, the strength of the produced joint, and its experimental verification. A good agreement between experimental and simulation results is observed with an error range of 5–12%. Furthermore, ANOVA analysis shows that the contribution % of thread angle, thread pitch, and discharge energy is 32.99%, 41.35%, and 19.22 %, respectively, towards strength.
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