Study on electromagnetic crimping of tube-to-rod for axial and torsional joint

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Dissimilar metal joints are widely used for the technical and economical reason in various industrial applications which involves lightweight design. To deal with all those challenges in conventional joining, advanced joining technology like electromagnetic crimping becomes prominent. Primarily, experiments were carried out to investigate the feasibility of (electromagnetic crimping) EM crimping of aluminum tube with steel rod using a single rectangular groove which includes the effects of discharge energies on the strength of a joint, radial displacement, and tube thickness reduction respectively. A numerical study was carried out initially to find a suitable coil dimension. A validated model was used to predict the effects of discharge energies on process parameters and to determine the best energy levels. For improving joint strength to support an axial load, a double rectangular groove was used. The numerical simulation is reasonably predicting mode of failure and process parameters. A significant effect of groove depth on the strength of the joint, groove filling, wrinkling, and tube thickness reduction was also studied. A practical design guideline that describes the effects of the width-to-depth ratio on the strength of a joint was proposed.
Supervisor: Sachin D. Kore