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Numerical Study and Experimental Investigation on Electromagnetic Crimping for Tube-to-Rod Configuration

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Abstract

Using low-density material like aluminum to reduce the weight of airframe structure becomes prominent and requires effective joining technology. Electromagnetic crimping is a high-speed joining method that deforms electrically conductive material by discharging high-voltage from the capacitor bank at room temperature. In this study, the effect of discharge energy on joint quality and process parameters is investigated numerically and experimentally. Finite element simulation and analysis were carried out using LS-DYNA™ software by its electromagnetic module. Effects of energies on the effective plastic strain, resultant velocity, displacement, Lorentz force, current densities, magnetic field densities, and maximum shear stress were predicted numerically to determine best energy levels. Based on the result obtained from numerical simulations, three levels of energy were chosen to conduct the experiment. Pull-out strength of the crimped sample was found 95% compared to the strength of the tube. A tube thickness reduction at groove edge, radial displacement of the tube, and groove filling obtained numerically were compared with experiment and found to be in a good agreement. The developed model can be used as a preliminary study to investigate the effect of groove and process parameter on joint quality.

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Abbreviations

E 1 :

Stored energy (J)

V :

Voltage (V)

C:

Capacitance (C)

I :

Current (A)

ω:

Frequency (Hz)

L :

Inductance (H)

β:

Damping coefficient

t :

Time (s)

σ :

Electrical conductive (S/m)

µ :

Magnetic permeability(H/m)

ε:

Electrical permittivity (F/m)

Ε :

Electric field (V/m)

ƒ:

Discharge frequency (Hz)

σy :

Yield stress (Pa)

Α and Β :

Yield strength parameters (Pa)

C :

Strain rate sensitivity

\(\varepsilon_{eff}^{p}\) :

Equivalent plastic strain

m :

Thermal softening index

M, K, C :

Structural, stiffness and damping matrix

Β m :

Magnetic flux density (T)

J :

Total current density (A/mm2)

J s :

Source current density (A/mm2)

\(\vec{A}\) :

Vector potential (V s/m)

Ø:

Electric scalar potential (J/s)

Η :

Magnetic field intensity (T)

r :

Radial displacement (mm)

F :

Lorentz force (N)

N :

Number of turn

l :

Length of the coil (mm)

δ :

Skin depth (mm)

\(\dot{\varepsilon }\) :

Plastic strain rate (1/s)

n :

Strain hardening index

T :

Operating temperature (K)

T R :

Room temperature (K)

T m :

Melting point temperature (K)

u, \(\vec{F}\) :

Nodal displacement and load vector

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Funding

Funding was provided by IITG.

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Authors and Affiliations

  1. Mechanical Engineering Department, Indian Institute of Technology Guwahati, Guwahati, Assam, 781 039, India

    Getu Tilahun Areda & Sachin D. Kore

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  1. Getu Tilahun Areda
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  2. Sachin D. Kore
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Correspondence to Getu Tilahun Areda.

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Areda, G.T., Kore, S.D. Numerical Study and Experimental Investigation on Electromagnetic Crimping for Tube-to-Rod Configuration. Int. J. Precis. Eng. Manuf. 20, 181–191 (2019). https://doi.org/10.1007/s12541-019-00083-3

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