An Experimental Study on the Groove Design for Joints Produced by Hydraulic Expansion Considering Axial or Torque Load

Marré, Michael; Rautenberg, Jens; Tekkaya, A. Erman; Zabel, Andreas; Biermann, Dirk; Wojciechowski, J.; Przybylski, Włodzimierz

doi:10.1080/10426914.2011.593232

Cited by 9 publications

(9 citation statements)

References 16 publications

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“…In recent years, there has been a growing utilization of deformation-assisted joining processes driven by an increasing demand of assembling lightweight components. Deformation-assisted joining processes are classified into three distinct groups according to their operating principles:Based on mechanical, hydraulic, and magnetic loading, such as clinching [1,2], self-pierce riveting [3], sheet-bulk compression [4], hydraulic forming [5], and electro-magnetic forming [6];Based on solid-state welding, such as friction stir welding [7], friction spot welding [8] and explosive welding [9];Based on fusion welding combined with plastic deformation, such as resistance spot and projection welding [10] and weldbonding [11]. …”

Section: Introductionmentioning

confidence: 99%

“…Based on mechanical, hydraulic, and magnetic loading, such as clinching [1,2], self-pierce riveting [3], sheet-bulk compression [4], hydraulic forming [5], and electro-magnetic forming [6];…”

Section: Introductionmentioning

confidence: 99%

“…The utilization of force-fit mechanical joints that exclusively rely on the pressure that remains on the contact interfaces after elastic recovery from mechanical [18], hydraulic [5], or magnetic loading [6] is not a feasible solution for the fixing of sheets to tubes due to the limited contact surfaces provided by the small thickness sheets that are commonly used in the industry (Figure 1d). Similar constraints apply to new developments for the joining of thick blocks (or plates) to tubes by compressing the upper end of a connecting block flange [19,20] because of the need to produce the connecting flange by machining.…”

Section: Introductionmentioning

confidence: 99%

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Deformation-Assisted Joining of Sheets to Tubes by Annular Sheet Squeezing

et al. 2019

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This paper is built upon the deformation-assisted joining of sheets to tubes, away from the tube ends, by means of a new process developed by the authors. The process is based on mechanical joining by means of form-fit joints that are obtained by annular squeezing (compression) of the sheet surfaces adjacent to the tubes. The concept is different from the fixing of sheets to tubes by applying direct loading on the tubes, as is currently done in existing deformation-assisted joining solutions. The process is carried out at room temperature and its development is a contribution towards ecological and sustainable manufacturing practices due to savings in material and energy consumption and to easier end-of-life disassembly and recycling when compared to alternative processes based on fastening, riveting, welding and adhesive bonding. The paper is focused on the main process parameters and special emphasis is put on sheet thickness, squeezing depth, and cross-section recess length of the punches. The presentation is supported by experimentation and finite element modelling, and results show that appropriate process parameters should ensure a compromise between the geometry of the mechanical interlocking and the pull-out strength of the new sheet–tube connections.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Deformation-Assisted Joining of Sheets to Tubes by Annular Sheet Squeezing

et al. 2019

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“…Sheet-tube joining by squeeze-grooving is an alternative to existing mechanical joining processes based on tube expansion with flexible rubber plugs 4 ( Figure 1(b)), pressurized fluids 5 (Figure 1(c)), and electromagnetic pressure 6 (Figure 1(d)), which are less cost-effective and efficient, and have difficulties to be used on site.…”

Section: Introductionmentioning

confidence: 99%

Mechanical joining of sheets to tubes by squeeze-grooving

Alves

Afonso

Martins

2019

Proceedings of the Institution of Mechanical Engineers, Part L:

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The purpose of this paper is to present a mechanical joining process to produce sheet-tube connections in a single stroke, at room temperature. The proposed solution is an enhancement of a previous joining by squeeze-grooving process that makes use of two independent mandrels and a customized spacer to control the inner joint radius and to improve its overall aesthetics. The presentation is illustrated with selected examples retrieved from experimentation and finite element modeling. Results show that the new proposed sheet-tube connections are characterized by a better redistribution of material within the joints and a very significant improvement of the pull-out strength. The proposed process also allows connecting a sheet to a tube close to the tube ends, which is impossible to achieve by means of the original joining by squeeze-grooving process.

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“…According to [7,8], the Insertion Height is related to the Heating Temperature of the insert, the Insertion Time, and the Insertion Load. These factors are directly linked to the material of the insert, the amount of polymer pushed during the insertion process, and the melting point of the polymer [9][10][11]. However, the equipment used in this research does not have an adjustment valve; as a result, the operator cannot change the value of the Insertion Load, which is kept constant at 5 bar by a lever system driven by a pneumatic cylinder.…”

Section: Introductionmentioning

confidence: 99%

Use of Factorial Designs and the Response Surface Methodology to Optimize a Heat Staking Process

2018

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The demand from the automotive industry for lighter and more resistant structures produced at lower costs has shifted the development focus of production processes toward hybrid components. A problem that arises from hybrid components is the necessity to join dissimilar materials, e.g., polymers and metals. A method to achieve this joining involves a process known as heat staking, in which a metal insert is heated and pushed against a thermoplastic surface. At the end of this process, the metal component may not be level with the thermoplastic surface; rather, it may be over flushed, and this discrepancy is known as the Insertion Height. This paper aims to apply the design of experiments and the response surface methodology to develop a model for the Insertion Height, considering the Heating Temperature and the Insertion Time as independent variables. The experiments revealed that the Insertion Height is most affected by the Heating Temperature. There are several combinations of the factors that can keep the Insertion Height within the specifications; therefore, it is possible to increase productivity by decreasing the Insertion Time and to save energy by reducing the Heating Temperature while considering the process constraints and specifications.

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An Experimental Study on the Groove Design for Joints Produced by Hydraulic Expansion Considering Axial or Torque Load

Cited by 9 publications

References 16 publications

Deformation-Assisted Joining of Sheets to Tubes by Annular Sheet Squeezing

Deformation-Assisted Joining of Sheets to Tubes by Annular Sheet Squeezing

Mechanical joining of sheets to tubes by squeeze-grooving

Use of Factorial Designs and the Response Surface Methodology to Optimize a Heat Staking Process

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