Influencing Factors on the Strength of Electromagnetically Produced Form-Fit Joints using Knurled Surfaces
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Date
2012-07-17
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Abstract
Joining by electromagnetic forming is a non-contact assembling method that is especially
suitable for connections in aluminum space frame structures. By reason of increased joint
strength along with lower charging energies, form-fit connections are favored over
interference-fit connections for this joining process. In contrast to conventional form-fit
concepts, in which the inner joining partner has grooves or pockets, the use of knurled
surfaces offers several advantages like easier machinability or the resistance against
combined axial and torsional loadings. The objective of this paper is to identify the
influencing geometry and process parameters on the joint strength of tubular joints using
mandrels with knurled surfaces, with tube and mandrel being made of the same aluminum
alloy AA6060-T6. For that reason, experimental studies were conducted: In addition to
pull-out tests to determine the axial strength of joints, first computed tomographic images
and, afterwards, micrographs of joined components were produced to analyze the contact
zone between tube and mandrel and the deformation behavior of the inner joining partner
by non-destructive and destructive means. Based on the detailed knowledge of the
influencing variables, guidelines for joint and process design are derived.
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Keywords
form-fit joints, joining by electromagnetic forming, lightweight frame structures