Abstract
Research works on the joining of shaft and plate are summarized and the features of the conventional caulking process are discussed. Maximum caulking force is limited by the occurrence of shaft buckling and plate warping. The joining force in upset caulking mainly results from press fit force between the hole wall of the plate and the enlarged shaft diameter, while the joining force in shear caulking mainly results from press fit force at the flange portion of the caulked head. To improve joint efficiency, a two-step process in which upset caulking is combined with shear caulking, is newly proposed. Optimum working conditions are examined and experimental results show considerable improvement of joining efficiency, especially in rotational resistance. Some ideas for the practical application of this process are proposed here.
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