Abstract
Electrohydraulic expansion joining has great potential for joining the light weight and high strength thin-walled pipes due to its high strain rate. Based on the central composite design (CCD) of response surface methodology, multiple experiments of electrohydraulic expansion joining process were performed. The multivariate quadratic nonlinear regression model between process parameters (discharge voltage, wire length, and wire diameter) and the ultimate pull-out load of the joints was established. The results revealed that discharge voltage, wire length and wire diameter all had a significant effect on the ultimate pull-out load. The discharge voltage had the most significant effect. The interaction between the discharge voltage and the wire diameter had a significant effect on the ultimate pull-out load. The optimal parameter combination (discharge voltage = 6 kV, wire length = 10 mm, wire diameter = 0.833 mm) was obtained and verified through the experiments. This study would provide guidance for the choice of the process parameters in real applications.
Highlights
In recent years, the weight reduction of vehicles has become the focus of the development of the automotive and aviation manufacturing industries [1,2,3]
Multiple experiments of electrohydraulic expansion joining based on the response surface methodology have been conducted
The results of the multivariate quadratic nonlinear regression model of the ultimate pull-out load of electrohydraulic expansion joints were in good agreement with the experimental results, which indicated that the model could accurately predict the ultimate pull-out load
Summary
The weight reduction of vehicles has become the focus of the development of the automotive and aviation manufacturing industries [1,2,3]. During the electro-magnetic crimping joining process, the discharge energy and the groove characteristics would affect the strength of the joint. In response to this characteristic, Weddeling et al established an analysis method for determining process parameters such as discharge energy based on groove geometry and workpiece characteristics in the joining process [4,17]. The experimental design method and mathematical statistical analysis method were applied to investigate the influence of discharge energy, wire length and wire diameter on the pull-out load of electrohydraulic expansion joints. The experimental results were statistically analyzed to obtain the multivariate nonlinear regression model of the ultimate pull-out load of electrohydraulic expansion joints based on response surface methodology. Experiments were carried out to verify the optimization results under the optimized settings
Sign-in/Register to view highlights & summary 
Published Version (
Free)
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call