Finite Element Simulation of the Presta Joining Process for Assembled Camshafts: Application to Aluminum Shafts

Abstract

This work shows a sequence of numerical models for the simulation of the Presta joining process: a well-established industrial process for manufacturing assembled camshafts. The operation is divided into two sub-steps: the rolling of the shaft to widen the cam seat and the joining of the cam onto the shaft. When manufactured, the connection is tested randomly by loading it with a static torque. Subsequently, there are three numerical models using the finite element method. Additionally, a material model of finite strain viscoplasticity with nonlinear kinematic hardening is used throughout the whole simulation process, which allows a realistic representation of the material behavior even for large deformations. In addition, it enables a transfer of the deformation history and of the internal stresses between different submodels. This work also shows the required parameter identification and the associated material tests. After comparing the numerical results with experimental studies of the manufacturing process for steel-steel connections, the models are used to extend the joining process to the utilization of aluminum shafts.

Light-Weight Aluminum-Based Alloys—From Fundamental Science to Engineering Applications

“…Consequently, Habisch et al [14] study the potential of diffusion-bonding of aluminum alloys and magnesium with different interlayer materials. Scherzer et al [15] report on a different kind of component; they present dedicated Finite Element simulations of the Presta joining process for assembled camshafts. Joining steel and aluminum in such a component is challenging, for instance, because of thermal expansion.…”