Single-stroke mechanical joining of sheet panels to tubular profiles

This paper proposes an innovative mechanical joining process for fixing sheet panels against tubular profiles with a single ram stroke.The presentation includes independent determination of the mechanical properties of sheets and tubes, finite element modelling and experimentation under laboratory conditions. The aim is to identify the key parameters of the process, to diagnose possible sources of failure and to understand the routes for selecting the most appropriate joining conditions.Results and observations show that fixing sheet panels to tubular profiles by tube forming with a single ram stroke is a flexible and cost-effective mechanical joining process that can be easily industrialized in a small capacity press. Applications may span for a wide range of engineering applications where conventional technologies based on fasteners, glueing with structural adhesives, brazing and soldering or welding cannot be employed due to technical, aesthetical or economic constraints.

► New mechanical joining process for fixing sheets against tubes with a single ram stroke.
► Technological window of the process defined as a function of the main operative variables.
► Process allows joining dissimilar materials (e.g. metals and polymers).
► Process requirements facilitate industrialization in a low-cost, small capacity, press.