A Novel Method of Joining a Rod to a Sheet by End Deformation: A Preliminary Experimental Study
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In the present work, a novel manufacturing process of joining a rod to a sheet has been proposed and demonstrated at the lab scale. The sheet is joined between two material accumulated regions of the rod. The material accumulations are nothing but deformation of rod at its end using a rigid tool. The process is performed in a lathe machine. Two different tool geometries are attempted for joining. It is demonstrated that a rod and a sheet are successfully joined by this method. During accumulation, the material not only gets sheared, but also gets curled, before joining occurs. Tool A produces stiffer joint as compared to tool B and a gas welded joint. Tool A produces larger curl/accumulation during first accumulation as compared to tool B. Pull-out tests on the joints made confirm the advantage of the proposed process over gas welded joint and the applicability of tool A over tool B. The hardness variation has no strong relation with tools used. Sliding of rod into the chuck and material removal without accumulation are the problems witnessed during experimentation.
KeywordsJoining Deformation Rod Sheet Manufacturing Sustainable
Depth of deformation
number of turns
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