Abstract
This paper proposes a new joining by forming process for connecting metal–polymer sandwich composite panels to metallic tubes. The process involves forming an annular flange with rectangular cross-section by partial sheet-bulk of the tube wall thickness and performing the mechanical interlocking by upsetting the free tube end against the sandwich composite with a flaring punch. The presentation addresses the main process variables and workability limits, and the overall conclusions are supported by experimentation and finite element analysis. Results show that the new proposed joining by forming process has potential to be used in mass production contributing, therefore, to extend the application of metal–polymer sandwich composites to structural components.
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