Abstract
This work explores the tube-to-tube joining of copper (outer) and stainless steel (inner) using electromagnetic crimping. Stand-off distance is kept constant during all the experiments. ls-dynaTM electromagnetic module, which utilizes finite element method combined with the boundary element method, is used to perform numerical simulations and the model is validated with experimentally observed thinning and radial deformation of the outer tube during electromagnetic crimping. Effect of slit of the field shaper on Lorentz force distribution is studied. It is observed that the slit of the field shaper leads to uneven radial deformation. Furthermore, a novel finite element model has been developed to predict the pull-out and compressive strength of the joint. Results are validated with the experimentally observed data.
Issue Section:
Research Papers
References
1.
Kumar
, R.
, and Kore
, S. D.
, 2017
, “Effects of Surface Profiles on the Joint Formation During Magnetic Pulse Crimping in Tube-to-Rod Configuration
,” Int. J. Precis. Eng. Manuf.
, 18
(8
), pp. 1181
–1188
. 10.1007/s12541-017-0138-92.
Simoen
, B.
, Faes
, K.
, and Waele
, W. D.
, 2017
, “Investigation of the Weldability of Copper to Steel Tubes Using the Electromagnetic Welding Process
,” Int. J. Sustain. Constr. Des.
, 8
(1
), pp. 1
–7
. 10.21825/scad.v8i1.68113.
Raoelisona
, R. N.
, Sapanathan
, T.
, Buiron
, N.
, and Rachik
, M.
, 2015
, “Magnetic Pulse Welding of Al/Al and Al/Cu Metal Pairs: Consequences of the Dissimilar Combination on the Interfacial Behavior During the Welding Process
,” J. Manuf. Process.
, 20
(1
), pp. 112
–127
. 10.1016/j.jmapro.2015.09.0034.
Patra
, S.
, Arora
, K.
, Shome
, M.
, and Bysakh
, S.
, 2017
, “Interface Characteristics and Performance of Magnetic Pulse Welded Copper-Steel Tubes
,” J. Mater. Process. Technol.
, 245
, pp. 278
–286
. 10.1016/j.jmatprotec.2017.03.0015.
Massalki
, T. B.
, Murray
, J. L.
, Bennet
, L. H.
, Baker
, H.
, and Kacprzak
, L.
, 1986
, Binary Alloy Phase Diagrams
, American Society for Metals
, Metals Park, Ohio
, Vols. 1 and 2
.6.
Oliveira
, I. V.
, Cavaleiro
, A. J.
, Taber
, G. A.
, and Reis
, A.
, 2017
, “Magnetic Pulse Welding of Dissimilar Materials: Aluminum-Copper,” Materials Design and Applications. Advanced Structured Materials
, 65
, L
Silva
, ed., Springer
, Cham
, pp. 419
–431
.7.
Kapil
, A.
, and Sharma
, A.
, 2015
, “Magnetic Pulse Welding: An Efficient and Environmentally Friendly Multi-Material Joining Technique
,” J. Cleaner Prod.
, 100
(1
), pp. 35
–58
. 10.1016/j.jclepro.2015.03.0428.
Shanthala
, K.
, Sreenivasa
, T. N.
, Murthy
, H. N. N.
, Dond
, S.
, Choudhury
, H.
, and Sharma
, A.
, 2019
, “Joining of Tubular Steel–Steel by Unconventional Magnetic Pulse Force: Environmentally Friendly Technology
,” Bull. Mater. Sci.
, 42
(6
), p. 260
. 10.1007/s12034-019-1947-59.
Pourabbasa
, M.
, Abdollah-zadeha
, A.
, Sarvaria
, M.
, Pouranvarib
, M.
, and Miresmaeilia
, R.
, 2019
, “Investigation of Structural and Mechanical Properties of Magnetic Pulse Welded Dissimilar Aluminum Alloys
,” J. Manuf. Process.
, 37
, pp. 292
–304
. 10.1016/j.jmapro.2018.12.00210.
Areda
, G.
, and Kore
, S. D.
, 2019
, “Numerical Study and Experimental Investigation on Electromagnetic Crimping for Tube-To-Rod Configuration
,” Int. J. Precis. Eng. Manuf.
, 20
(2
), pp. 181
–191
. 10.1007/s12541-019-00083-311.
Pawar
, S.
, Kore
, S. D.
, and Nandy
, A.
, 2020
, “Comparison of Sheared Edge Zones Developed in Electromagnetic and Quasistatic Dieless Perforation
,” J. Materi. Eng. Perform.
, 29
(2
), pp. 1146
–1155
. 10.1007/s11665-020-04636-w12.
Rajak
, A.
, and Kore
, S. D.
, 2017
, “Experimental Investigation of Aluminium–Copper Wire Crimping with Electromagnetic Process: Its Advantages Over Conventional Process
,” J. Manuf. Process.
, 26
, pp. 57
–66
. 10.1016/j.jmapro.2017.01.00913.
Repetto
, E. A.
, Radovitzky
, R.
, Ortiz
, M.
, Lundquist
, R. C.
, and Sandstrom
, D. R.
, 1999
, “A Finite Element Study of Electromagnetic Riveting
,” ASME J. Manuf. Sci. Eng.
, 121
(1
), pp. 61
–68
. 10.1115/1.283057614.
Lai
, Z.
, Cao
, Q.
, Han
, X.
, Chen
, M.
, Liu
, N.
, Li
, X.
, Cao
, Q.
, Huang
, Y.
, Chen
, Q.
, and Li
, L.
, 2019
, “Insight Into Analytical Modelling of Electromagnetic Forming
,” Int. J. Adv. Manuf. Technol.
, 101
(9-12
), pp. 2585
–2607
. 10.1007/s00170-018-3090-715.
Yu
, H.
, Li
, C.
, and Deng
, J.
, 2009
, “Sequential Coupling Simulation for Electromagnetic–Mechanical Tube Compression by Finite Element Analysis
,” J. Mater. Process. Technol.
, 209
(2
), pp. 707
–713
. 10.1016/j.jmatprotec.2008.02.06116.
Khan
, M. R.
, Hossain
, M. M.
, Sharma
, A.
, and Kumar
, S.
, 2019
, “Sequential Coupling of Electromagnetic– Structural Simulation for Compression Welding of Tubular Jobs
,” J. Mech. Eng. Sci.
, 233
(10
), pp. 3346
–3355
. 10.1177/095440621881344517.
Kumar
, D.
, Pawar
, S.
, Kore
, S. D.
, and Nandy
, A.
, 2020
, “Comparison of Coupled and Non-Coupled Finite Element Models for Joining of Cu-SS Tubes by Electromagnetic Forming
,” Procedia Manuf.
, 47
, pp. 673
–677
. 10.1016/j.promfg.2020.04.20818.
Chaharmiri
, R.
, and Arezoodar
, A. F.
, 2017
, “The Effect of Stepped Field Shaper on Magnetic Pressure and Radial Displacement in Electromagnetic Inside Bead Forming: Experimental and Simulation Analyses Using Maxwell and Abaqus Software
,” ASME J. Manuf. Sci. Eng.
, 139
(6
), p. 061003
. 10.1115/1.403521919.
Weddeling
, C.
, Demir
, O. K.
, Haupt
, P.
, and Tekkaya
, A. E.
, 2015
, “Analytical Methodology for the Process Design of Electromagnetic Crimping
,” J. Mater. Process. Technol.
, 222
, pp. 163
–180
. 10.1016/j.jmatprotec.2015.02.04220.
Yu
, H.
, and Li
, C.
, 2007
, “Effect Of Coil Length on Tube Compression in Electromagnetic Forming
,” Trans. Nonferrous Met. Soc. China
, 17
(6
), pp. 1270
–1275
. 10.1016/S1003-6326(07)60261-121.
Yu
, H.
, Li
, C.
, Liu
, D.
, and Mei
, X.
, 2010
, “Tendency of Homofeneous Radial Deformation During Electromagnetic Compression of Aluminium Tube
,” Trans. Nonferrous Met. Soc. China
, 20
(1
), pp. 7
–13
. 10.1016/S1003-6326(09)60089-322.
Yu
, H.
, 2006
, Buckling Criteriation and Deformation Analysis of Electromagnetic Tube Compression [D]
, Harbin Institute of Technology
, Harbin
, pp. 70
–71
(in Chinese).23.
Yu
, H.
, Li
, C.
, Zhao
, Z.
, and Li
, Z.
, 2005
, “Effect of Field Shaper on Magnetic Pressure in Electromagnetic Forming
,” J. Mater. Process. Technol.
, 168
(2
), pp. 245
–249
. 10.1016/j.jmatprotec.2005.01.00124.
Khan
, M. R.
, Hossain
, M. M.
, Sharma
, A.
, and Kumar
, S.
, 2019
, “Predicting the Effect of Field Shaper in Electromagnetic Welding Using FEM
,” Arab J. Sci. Eng.
, 44
(2
), pp. 1129
–1136
. 10.1007/s13369-018-3430-925.
Bahmani
, M.
, Niayesh
, K.
, and Karimi
, A.
, 2009
, “3D Simulation of Magnetic Field Distribution in Electromagnetic Forming Systems with Field-Shaper
,” J. Mater. Process. Technol.
, 209
(5
), pp. 2295
–2301
. 10.1016/j.jmatprotec.2008.05.02426.
Zhang
, P.
, Kimchi
, M.
, Shao
, H.
, Gould
, J. E.
, and Daehn
, G. S.
, 2004
, “Analysis of the Electromagnetic Impulse Joining Process with a Field Concentrator
,” AIP Conf. Proc.
, 712
(1
), pp. 1253
–1258
. 10.1063/1.176670127.
L'Eplattenier
, P.
, Cook
, G.
, Ashcraft
, C.
, Burger
, M.
, Imbert
, J.
, and Worswick
, M.
, 2009
, “Introduction of an Electromagnetism Module in LSDYNA for Coupled Mechanical-Thermal-Electromagnetic Simulations
,” Steel Res. Int.
, 80
(5
), pp. 351
–358
.28.
Neugebauer
, R.
, Psyk
, V.
, and Scheffler
, C.
, 2012
, “Simulation of Electromagnetically Formed Joints
,” 5th International Conference on High Speed Forming
, Dortmund, Germany
, April
, pp. 219
–228
.29.
Neugebaeur
, R.
, Bouzakis
, K.-D.
, Denkena
, B.
, Klocke
, F.
, Sterzing
, A.
, Tekkaya
, A. E.
, and Wertheim
, R.
, 2011
, “Velocity Effects in Metal Forming and Machining Processes
,” CIRP Ann. Manuf. Techn.
, 60
(2
), pp. 627
–650
. 10.1016/j.cirp.2011.05.00130.
Sapanathan
, T.
, Yang
, K.
, Chernikov
, D.
, Raoelison
, R. N.
, Gluschenkov
, V.
, Buiron
, N.
, and Khan
, M. R.
, 2016
, “Thermal Effect During Electromagnetic Pulse Welding Process
,” Mater. Sci. Forum
, 879
, pp. 1662
–1667
. 10.4028/www.scientific.net/MSF.879.166231.
Psyk
, V.
, Risch
, D.
, Kinsey
, B.
, Tekkaya
, A.
, and Kleiner
, M.
, 2011
, “Electromagnetic Forming—A Review
,” J. Mater. Process. Technol.
, 211
(5
), pp. 787
–829
. 10.1016/j.jmatprotec.2010.12.01232.
Maria
, C.
, 2009
, Technology of EHIS (Stamping) Applied to Production of Automotive Parts
, Saint-Petersburg State Polytechnical University, Department of Applied Mathematics
, Saint Petersburg
.33.
Eric
, A. S.
, and Steven
, J. H.
, 2008
, “The Use of LS-DYNA® Models to Predict Containment of Disk Burst Fragments
,” 10th International LS-DYNA® Users Conference
, MI
.34.
Ls-Dyna Keyword User's Manual Version 971
. Livermore Software Technology Corporation, Livermore, 2007.35.
ASTM International
, 2016
, E8/E8M-16a Standard Test Methods for Tension Testing of Metallic Materials
, ASM International
, West Conshohocken, PA
.Copyright © 2020 by ASME
You do not currently have access to this content.
