Abstract
This paper presents a new joining method by a forming process for attaching sheets to tube ends. The process consists of two different forming stages carried out sequentially in a single stroke. Firstly, the free tube end is flared by compression with a contoured die, then is squeezed (indented) against the sheet surface to create a mechanical interlocking. The new process is carried out at an ambient temperature and, in contrast to existing joining by forming operations based on tube expansion, it avoids seal welds, tube protrusions above the sheet surfaces, and machining of grooves on the sheet holes to obtain the form-fit joints. The paper starts by analyzing the process deformation mechanics and its main operating variables and finishes by presenting examples that demonstrate its effectiveness for attaching sheets to tube ends made from polyvinylchloride and aluminum. Experimental and numerical simulation work provides support to the presentation.
Highlights
Single-Stroke Attachment of Sheets toThe processes for attaching metal sheets to metal tube ends can be classified into two main groups: (i) joining by forming processes and (ii) fusion welding processes
To obtain in a combination process for attaching sheets to tube ends made from dissimilar materials (polymer and metand homogeneous plastic material flow and (iii) the applicability to sheets and tubes made als) in a single operation by means of a form-fit predominantly from dissimilar materials
Joining by flaring and sheet squeezing was successfully extended to the attachment of sheet to tube ends made from dissimilar materials
Summary
The processes for attaching metal sheets to metal tube ends can be classified into two main groups: (i) joining by forming processes and (ii) fusion welding processes. In case of sheet-tube components involving polymers and metals, the state-of-the-art review on the joining of dissimilar materials by Martinsen [8] allows concluding that joining by forming has potential to be an alternative to existing adhesive bonding processes This is important because the use of adhesives is limited by surface preparation, by temperature and environmental conditions, by difficulties in disassembling the individual parts at the end of service life and by the use of clamps, jigs and fixtures to lock and hold the sheets and tubes in position during the curing time. The process was successfully applied to connect metal rings (sheets) to the metal tube ends, and is based on a force-fit joining mechanism relying on the residual normal pressures that are created at the contact interfaces after unloading Application of this process to sheet-tube attachments made from dissimilar materials is feasible but there is a risk of cracking the outer sheet edges and an elevated risk of sheet buckling after removing the component from the tool. The paper to analyze the be main differ‐to characterize plastic material flow inside the sheet thickness, and to establish the fundamental design ences in the overall process deformation mechanics when the new process is applied to guidelines to produce sound form-fit joints
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