Finite Element Modeling of Electromagnetic Crimping of Cu-SS Tube-to-Tube Joint Along With Simulation of Destructive Testing for Strength Prediction of the Joint

Abstract This work explores the tube-to-tube joining of copper (outer) and stainless steel (inner) using electromagnetic crimping. Stand-off distance is kept constant during all the experiments. ls-dynaTM electromagnetic module, which utilizes finite element method combined with the boundary element method, is used to perform numerical simulations and the model is validated with experimentally observed thinning and radial deformation of the outer tube during electromagnetic crimping. Effect of slit of the field shaper on Lorentz force distribution is studied. It is observed that the slit of the field shaper leads to uneven radial deformation. Furthermore, a novel finite element model has been developed to predict the pull-out and compressive strength of the joint. Results are validated with the experimentally observed data.