23 research outputs found
Electromagnetic Form-Fit Joining
As a way to reduce a vehicle's weight, the application of space frame structures has been increasing. This innovative lightweight design concept is already commonly applied in the low volume production of cars. Due to the high stiffness and low mass, extruded aluminum profiles are particularly suitable for the manufacturing of such structures. But the potential for great weight reduction using space frames is curtailed by the difficulties associated with manufacturing the space frames. These structures have complex demands on joining technologies, and conventional processes often are pushed to their technological limits.
A promising alternative to connect extruded aluminum profiles without heating or penetration is joining by electromagnetic crimping. Compared to adhesive bonding and welding, the process also requires a less extensive preparation of the joining zone. This technique is characterized by the use of pulsed magnetic fields to form a profile made of an electrically conductivity material into form-fit elements, like grooves, of the other joining partner. Thereby, an interlock is generated which enables the load transfer.
A fundamental process understanding of the manufacturing and the load transfer of form-fit connections manufactured by electromagnetic crimping is developed in this thesis. Based on analytical, experimental, and numerical studies, major parameters are identified and their influence on the joining process and the achievable joint strength is analyzed. For the analytical investigations a continuous approach describing the manufacturing of the connections as well as the load transfer is introduced here. This model also facilitates the process and joining zone design of electromagnetically crimped connections
Investigation of Tailored Pressure Distributions by Vaporizing Tailored Foils
The rapid vaporization of thin metallic conductors can be used for innovative high speed
forming processes. Metal wires or foils are vaporized when a high current is applied. The
generated metal gas or plasma expands very rapidly with high pressure and impacts on
an intermediate polyurethane plate near the wires or foils. A shock wave is induced into
the polyurethane plate and provides the pressure pulse to the sheet metal, leading to a
deformation of the sheet. This process requires no expensive tool coils and no electrical
conductivity of the workpiece, which makes it attractive to multiple fields of application
such as forming and impact welding. In this study, the basic process parameters that
influence the shock pressure were experimentally identified including the charging energy
of capacitor bank, foil geometry (thickness and width) and thickness of polyurethane plate.
Based on the experiments of the parameter investigations, different new foil designs were
investigated in order to acquire a tailored pressure distribution. The results show that the
shock pressures can be located at different positions in a discontinuous way. Besides, the
pressure amplitudes and areas at different positions can also be varied, which depends
on the vaporized foil geometries at those positions
Experimental Investigations on the Optimum Driver Configuration for Electromagnetic Sheet Metal Forming
Electromagnetic forming is a high speed forming process especially suitable for materials
with high electrical conductivity such as copper or aluminum. In case of materials with
comparatively low electrical conductivity (e.g. stainless steel or titanium) the use of
so-called driver sheets is a common approach. Various publications proved that this way
materials with low electrical conductivity and even non-conductive materials can be
formed. Although the use of driver sheets is common practice, there are no or only
contradicting recommendations regarding the optimum driver sheet configuration.
Based on experimental investigations of the electromagnetic sheet metal forming process,
this paper investigates the optimum material and thickness of the driver sheet. The results
prove that aluminum should be favored over copper as driver material. The optimum
driver thickness was found to be dependent on thickness and electrical conductivity of the
workpiece. Even in case of a workpiece made of aluminum the use of a driver sheet could
enhance the efficiency of the process
Avoiding Bending in Case of Uniaxial Tension with Electromagnetic Forming
During electromagnetic forming, excessive bending of the specimen takes place due to
high velocities and inertia. We show that the excessive bending can be prevented by
optimizing the coil geometry in case of uniaxial tension. The process is simulated with
various coil geometries, and the resulting amount of bending is compared to the case of
standard Nakajima Test. The comparison shows that the bending can be minimised to
acceptable levels to be able to call the method a decent way of determining forming limits.
The results should be verified experimentally
Agile Production of Sheet Metal Aviation Components Using Disposable Electromagnetic Actuators
Electromagnetic forming is a process used to produce high strain rates that improve the formability of sheet metal. The objective of this paper is to discuss the feasibility of the use of disposable actuators during electromagnetic forming of two aluminum components: an industry part whose main feature is a convex flange with two joggles, and a simple part with a one-dimensional curve throughout. The main forming complications after the parts were formed using conventional methods were the presence of wrinkles and excessive springback. The goal of this work is to use large, controlled electromagnetic impulses to minimize the springback of these components from a roughformed shape, with the end result being a dimensionally correct part. The optimum test protocols for electromagnetic calibration of the components were determined by optimizing parameters such as design of the actuator, tool material, and capacitor discharge energy. The use of disposable actuators for electromagnetic calibration of the parts showed significant reductions in springback compared to the parts which were only preformed using conventional techniques (hydroforming and rubber-pad forming). Springback was decreased in the curved component by up to 87%. For the flanged component, the wrinkles were eliminated, the joggles were formed properly, and the average bending angle of the part was improved from 95.3° to 90.3°, very near the target bending angle of 90°. This study demonstrates that these forming techniques can be used to improve current sheet metal production processes
Influence of Axial Workpiece Positioning during Magnetic Pulse Welding of Aluminum-Steel Joints
Magnetic Pulse Welding (MPW) offers a method to economically join similar and dissimilar
metals without the need for external physical or chemical binders, while avoiding the
adverse heating effects seen in many welding techniques. MPW allows for the fabrication
of joints via the harnessing of Lorentz forces, which result from discharging a current
pulse through a coil. In the process an outer piece (flyer) is accelerated onto an inner
piece (parent), and welding is achieved using propagating impact fronts. There are
several geometrical factors to be considered including the flyer-coil distance, the parentflyer
distance, as well as the axial relationship between flyer and coil (working length).
Various shapes of the front are possible and each configuration has its own advantages
and drawbacks. The goal of this work is to show not only how the aforementioned
parameters are related, but also ways to optimize front propagations, which are vital to the
welding result. This is done primarily by determining the influence of the working length of
tubular MPW specimens. It is shown that for steel-aluminum joints in the given
arrangements, three different front regimes exist, which are related to geometrical factors.
These results are especially useful to avoid seemingly favorable but nevertheless
suboptimal conditions for flyer movement that would reduce weld quality and energy
efficiency of the process
Development of design principles for form-fit joints in lightweight frame structures
Based on fundamental technological investigations, alternative joining strategies using electromagnetic forming (EMF) for the flexible production of lightweight frame structures are developed in the collaborative research project SFB/TR10. The results of these investigations will also be used to create general design principles for the joining process itself as well as for the joining zone. The focus of this article will be on dominating form-fit joints of aluminum frame structures and the parameters which have a significant influence on the strength of those joints. For the development of design principles regarding the joining zone, the groove geometry of the connection elements was varied in terms of size and shape, and the influence of those variations was analyzed. In terms of the joining process itself the effect on the joint strength of different forming pressures for a given groove geometry was also investigated. In the first step these experiments were performed on solid mandrels. In order to reduce the weight of the structure, experiments were then performed with hollow connection elements and similar groove geometries to analyze how the reduced stiffness of those elements affected the strength of the joints
Influencing Factors on the Strength of Electromagnetically Produced Form-Fit Joints using Knurled Surfaces
Joining by electromagnetic forming is a non-contact assembling method that is especially
suitable for connections in aluminum space frame structures. By reason of increased joint
strength along with lower charging energies, form-fit connections are favored over
interference-fit connections for this joining process. In contrast to conventional form-fit
concepts, in which the inner joining partner has grooves or pockets, the use of knurled
surfaces offers several advantages like easier machinability or the resistance against
combined axial and torsional loadings. The objective of this paper is to identify the
influencing geometry and process parameters on the joint strength of tubular joints using
mandrels with knurled surfaces, with tube and mandrel being made of the same aluminum
alloy AA6060-T6. For that reason, experimental studies were conducted: In addition to
pull-out tests to determine the axial strength of joints, first computed tomographic images
and, afterwards, micrographs of joined components were produced to analyze the contact
zone between tube and mandrel and the deformation behavior of the inner joining partner
by non-destructive and destructive means. Based on the detailed knowledge of the
influencing variables, guidelines for joint and process design are derived
Routine habitat switching alters the likelihood and persistence of infection with a pathogenic parasite
Animals switch habitats on a regular basis, and when habitats vary in suitability
21 for parasitism, routine habitat switching alters the frequency of parasite exposure
22 and may affect post-infection parasite proliferation. However, the effects of
23 routine habitat switching on infection dynamics are not well understood.
24 2. We performed infection experiments, behavioural observations, and field
25 surveillance to evaluate how routine habitat switching by adult alpine newts
26 (Ichthyosaura alpestris) influences infection dynamics of the pathogenic parasite,
27 Batrachochytrium dendrobatidis (Bd).
28 3. We show that when newts are exposed to equal total doses of Bd in aquatic
29 habitats, differences in exposure frequency and post-exposure habitat alter
30 infection trajectories: newts developed more infections that persisted longer when
31 doses were broken into multiple, reduced-intensity exposures. Intensity and
32 persistence of infections was reduced among newts that were switched to
33 terrestrial habitats following exposure.
34 4. When presented with a choice of habitats, newts did not avoid exposure to Bd,
35 but heavily infected newts were more prone to reduce time spent in water.
36 5. Accounting for routine switching between aquatic and terrestrial habitat in the
37 experiments generated distributions of infection loads that were consistent with
38 those in two populations of wild newts.
39 6. Together, these findings emphasize that differential habitat use and behaviours
40 associated with daily movement can be important ecological determinants of
41 infection risk and severity.
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