Abstract
Electrohydraulic forming is a high-speed process, which is based on a force transmission by a working media. In this process, shock waves transmit the punching force in a very short period of time. These shock waves are applied to accelerate the workpiece towards a passive die. Besides forming and embossing of sheets and tubes, joining of sheets with tubes is enabled as a novel application presented in this contribution. Thereby, the tube is embedded temporarily in the die as a functional part. By accelerating the sheet towards the tube end, the joint is formed. This study deals with the question of how this joint is formed in sense of process kinematics and material flow. Therefore, the loading energy, the distance of sheet and tube as well as the sheet thickness was varied and the influence of these parameters and geometric conditions of the tube on the process and resulting joints was observed. Joining of EN AW-1050 aluminum alloy sheets to EN AW-6060 aluminum alloy tubes was performed. These joints were analyzed by microsections and head tension tests. The investigations introduce the new joining process regarding its process behavior and show first joining results.
Highlights
In manufacturing technical products, the number of parts and their complexity including diverse combinations of dissimilar materials increased
A well-known example is the integration of fiber-reinforced plastics such as tubes and plates made of natural fibers [2]
The increase of interlock volume for increased loading energy flattens due to strain hardening and further effects related to friction
Summary
The number of parts and their complexity including diverse combinations of dissimilar materials increased. A well-known example is the integration of fiber-reinforced plastics such as tubes and plates made of natural fibers [2]. Metals feature high strength and ductility to be shaped into small complex parts that can be exposed to multidimensional load. The combination of both materials bears high potential for weight reduction at reasonable costs. As material properties differ between fiber-reinforced plastics and metals, only few joining processes fulfill the demands. A further challenge is the varying geometry (high tolerances) of semi-finished products made of natural fibers - like the inner and outer diameter of tubes
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