Mechanical joining processes provide various advantages over conventional fusion welding of metallic components such as shorter cycle times, little or no heat input and reduced need for subsequent surface finishing operations. Several investigations in the past have shown that joints between tubes and sheets or plates can be manufactured by upsetting operations. Under axial compression, the tube develops a plastic instability in form of bulge. In-between two such bulges, a force and form fit to sheet material can be created. Previous work concentrated on forming fully developed bulges, i.e., at the end of the bulging process, both hinges of the bulge are in contact. This paper presents a numerical and experimental study aiming at optimizing the bulge shape to increase the bearable limit loads. Two new bulge designs are investigated, an 'arrow bulge' and a 'wave bulge'. The paper details the results of FE-simulations of the bulge shapes under bending and torsion loads. Forming tools were designed and both bulge shapes were produced experimentally. The results show that the material flow under compressive plastic instability can be controlled and that the resulting bulge shapes yield improved strength in various load cases
