Experimental and numerical studies on joining steel tubes by end forming

• Published in: Journal of constructional steel research Vol. 167; p. 105792
• Main Authors: Agrawal, Arvind K., Narayanan, R. Ganesh
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01-04-2020
• Subjects: End beading; End forming; End inversion; Joining; Simulation; Tube; End beading; Joining; Tube; End forming; Simulation; End inversion
• ISSN: 0143-974X; 1873-5983
• DOI: 10.1016/j.jcsr.2019.105792

The present article is focused on the development of a novel method of joining two steel tubes of different diameters at their ends by plastic deformation. A single stroke environmental friendly joining process consisting of tube end inversion and tube end beading has been developed. The proposed technology has the potential to replace the existing methods of joining such as welding, adhesive bonding, and joining by fasteners. The process has been modeled and analyzed in Abaqus finite element code, and the influence of important parameters on the joining formation has been identified. A number of criteria have been developed which can predict the quality of the joint at the shop floor. Demonstration of few selected cases on lab scale enhances the feasibility of the operation at the industrial level. The load-displacement behavior has been predicted, and validated with experiments. Out of all the parameters, projected height of punch, and circular arc radius are more influencing parameters. Mechanical testing of fabricated joints has been done using pull-out tests and compression tests. The strength of the fabricated joints compared well with the tube-to-tube joint made by arc welding. An alternative solution for joining of longer tubes has also been developed.
•A novel method of joining of tubes has been proposed.•Lab scale demonstration performed successfully.•Experimental and numerical load prediction matched well.•Strength of endformed joints comparable with welded joint.•Strategy to join longer tubes proposed.