TY - JOUR

T1 - Analytical model to determine the strength of form-fit connection joined by die-less hydroforming

AU - Weddeling, Christian

AU - Gies, Soeren

AU - Ben Khalifa, Noomane

AU - Tekkaya, A. Erman

N1 - Paper No: MANU-14-1639

PY - 2015/10/1

Y1 - 2015/10/1

N2 - Modern lightweight concept structures are increasingly composed of several dissimilar materials. Due to the different material properties of the joining partners, conventional and widely used joining techniques often reach their technological limits when applied in the manufacturing of such multimaterial structures. This leads to an increasing demand for appropriate joining technologies, like joining by die-less hydroforming (DHF) for connecting tubular workpieces. The present work introduces an analytical model to determine the achievable strength of form-fit connections. This approach, taking into account the material parameters as well as the groove and tube geometry, is based on a membrane analysis assuming constant wall thicknesses. Besides a fundamental understanding of the load transfer mechanism, this analytic approach allows a reliable joining zone design. To validate the model, experimental investigations using aluminum specimens are performed. A mean deviation between the calculated and the measured joint strength of about 19% was found. This denotes a good suitability of the analytical approach for the design process of the joining zone.

AB - Modern lightweight concept structures are increasingly composed of several dissimilar materials. Due to the different material properties of the joining partners, conventional and widely used joining techniques often reach their technological limits when applied in the manufacturing of such multimaterial structures. This leads to an increasing demand for appropriate joining technologies, like joining by die-less hydroforming (DHF) for connecting tubular workpieces. The present work introduces an analytical model to determine the achievable strength of form-fit connections. This approach, taking into account the material parameters as well as the groove and tube geometry, is based on a membrane analysis assuming constant wall thicknesses. Besides a fundamental understanding of the load transfer mechanism, this analytic approach allows a reliable joining zone design. To validate the model, experimental investigations using aluminum specimens are performed. A mean deviation between the calculated and the measured joint strength of about 19% was found. This denotes a good suitability of the analytical approach for the design process of the joining zone.

KW - form-fit joints

KW - joining by hydroforming

KW - space frame structure

KW - Engineering

UR - http://www.scopus.com/inward/record.url?scp=84941072099&partnerID=8YFLogxK

U2 - 10.1115/1.4030878

DO - 10.1115/1.4030878

M3 - Journal articles

AN - SCOPUS:84941072099

VL - 137

JO - Journal of Manufacturing Science and Engineering

JF - Journal of Manufacturing Science and Engineering

SN - 1087-1357

IS - 5

M1 - 051014

ER -