Abstract

Joining by hydraulic expansion is a well-investigated process to create force- and form-fit joints. In order to extend the application possibilities of this technology, the process of joining by die-less hydroforming with outer pressurization is developed. In this process, the force-fit is a result of an elastic springback restriction of the inner joining partner, caused by an elastic-plastic compression of the outer joining partner. The influence of the chosen materials on the establishment of a force-fit connection is investigated both numerically and experimentally. In this context, the ratio of the maximum elastic strains λ is introduced. For values of λ close to 1, the interference pressure is rather a result of the difference in the hardening gradient than of a restricted elastic springback. For values of λ close to 0 in turn, the interference pressure is a result of a restricted elastic springback. The obtained numerical data is validated with the experimental results for tube-to-tube connections of the aluminum alloys EN AW-2007 with EN AW-6060 and EN AW-6060 O, respectively.

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