Joining Sheets to Tubular Profiles by Tube Forming

Abstract

This chapter presents an innovative forming process for joining sheet panels to tubular profiles at room temperature. Finite element analysis and experimentation are utilized to understand the deformation mechanics of the process, to identify the operational feasibility window, and to discuss the capabilities across the useful range of working conditions. The feasibility of the proposed joining process is demonstrated by presenting conceptual applications and industrial prototypes comprising a seat-back bottom frame and an automotive hand-brake system. Results show that joining sheets to tubular profiles by means of tube forming can successfully replace conventional joining technologies based on mechanical fixing with fasteners, welding, or structural adhesive bonding.