Abstract
Electromagnetic crimping (EMC) is one of the advanced manufacturing technologies used to join lightweight material including metals with metallurgical and thermal property differences. This paper investigates EMC process numerically to deform aluminum tube (Al6061-T6) to the steel profiled rod using the electromagnetic (EM) module of LS-DYNATM. Electromagnetic crimping methods can join multiple material systems without melting. A longitudinal groove was designed on steel rod for mechanical interlocking to resist the torsional load. Groove geometrical parameters like groove length, depth, edge radius, and width were kept constant. Effects of voltage on an effective plastic strain, resultant impact velocity, resultant displacement, and temperature were studied in detail. Moreover, the simulation was carried out also to analyze the effect of capacitance on process parameters, and results are discussed in detail. The developed model is validated and found in a good agreement with experiment. Based on the results found, it is possible to predict essential process parameters for enhanced joint strength.
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