FORMING PROCESS SIMULATION OF BIMETALLIC BILLET BY EXTRUSION FOR REW METHOD

Alexander Schrek,Pavol Sejč,Branislav Vanko,Alena Brusilová

doi:10.36547/ams.27.4.1254

Abstract

The bimetallic joining elements were designed for lap joints of thin metallic (Fe-Fe, Fe-Al) as well as metallic – nonmetallic (Fe-PMMA, Al-PMMA) sheets by Resistance Element Welding (REW). The Cu tubes with an outer diameter of 4 mm, wall thickness of 0.5 mm, and a length of 11 mm filled with a solder Sn60Pb40 were used for the bimetallic joining elements producing. The required shape of joining elements is obtained by cold forming. Simulation by ANSYS software was chosen for the optimization of the forming process and geometry of functional parts of the forming tool allowing to use only one extrusion forming operation. The simulation results are stresses, strains, and modification of cross-section geometry of elements for the three proposed forming modes. The geometry of functional parts of the forming tool was compared with the results of cross-section macroanalysis of joining elements.

Highlights

Resistance Element Welding (REW) is one of the new joining methods applicable for joining the blanks of metallurgically unjoinable materials (Al-Fe, Plastic-Fe) [1 - 4]
During joining steel to aluminium, the joining element end is brazed to the steel blank while the aluminium blank is bonded in a joint only through the mechanical wedging
For the desired dimensions of the joining element used for the REW (Fig. 1), the billet created from a bimetallic bar (Cu tube filled with a Sn60Pb40 solder) divided in the length of 11 mm was used

Summary

INTRODUCTION

Resistance Element Welding (REW) is one of the new joining methods applicable for joining the blanks of metallurgically unjoinable materials (Al-Fe, Plastic-Fe) [1 - 4]. This method is intended to create lap joints. The problem that occurs in this solution is in splashing of the melted material of the head of the joining element, which causes worse functional and aesthetic joint characteristics. For the desired dimensions of the joining element used for the REW (Fig. 1), the billet created from a bimetallic bar (Cu tube filled with a Sn60Pb40 solder) divided in the length of 11 mm was used. Computer simulations and practical experiments were used for a verification of the proposed alterations [18-20]

MATERIAL AND METHODS

RESULTS AND DISCUSSION

CONCLUSION