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<p>The increasing demand for lightweight, high-strength dissimilar metal structures in aerospace and automotive industries necessitates the application of advanced computational tools for joining processes. In this study, smoothed-particle hydrodynamics (SPH) is employed to model the deformation behavior of copper-steel tube-to-tube joints formed via electromagnetic crimping (EMC), a high-speed, solid-state joining technique utilizing a pulsed electromagnetic field to join electrically conductive flyer tube onto the target. The SPH approach is compared to non-coupled FEM simulations and macrostructural experimental validation, highlighting its superior capability in capturing the complex material flow and localized plastic deformation, which is further used to derive empirical relations using bisquare and LAR methods to eventually minimize experimental trials. Analytical calculations are performed to estimate magnetic field intensity and crimping force, providing theoretical support to the computational analysis. Furthermore, joint strength (tensile and compressive) and the respective failure modes of the joints are predicted and compared with experimental results with 9-10% accuracy to highlight the importance of advanced computational tools in dissimilar metal joining.</p>

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Advanced Computational Approaches for Dissimilar Metal Electromagnetic Crimping: Comparing Smoothed-Particle Hydrodynamics and FEM

  • 期刊论文

  • 发表日期：

    2025年10月27日

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  • Deepak Kumar,
  • E. S. Shafeeque,
  • Sachin D. Kore,
  • Taeseon Lee,
  • Arup Nandy

摘要

The increasing demand for lightweight, high-strength dissimilar metal structures in aerospace and automotive industries necessitates the application of advanced computational tools for joining processes. In this study, smoothed-particle hydrodynamics (SPH) is employed to model the deformation behavior of copper-steel tube-to-tube joints formed via electromagnetic crimping (EMC), a high-speed, solid-state joining technique utilizing a pulsed electromagnetic field to join electrically conductive flyer tube onto the target. The SPH approach is compared to non-coupled FEM simulations and macrostructural experimental validation, highlighting its superior capability in capturing the complex material flow and localized plastic deformation, which is further used to derive empirical relations using bisquare and LAR methods to eventually minimize experimental trials. Analytical calculations are performed to estimate magnetic field intensity and crimping force, providing theoretical support to the computational analysis. Furthermore, joint strength (tensile and compressive) and the respective failure modes of the joints are predicted and compared with experimental results with 9-10% accuracy to highlight the importance of advanced computational tools in dissimilar metal joining.