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Electromagnetic crimping is a high-velocity joining method to join highlyconductive workpieces where a pulsed magnetic field is applied without anyworking medium or mechanical contact to deform the workpiece. This workexplores tube-to-tube joining of Copper outer tube and Stainless steel threadedinner tube using electromagnetic crimping. A non-coupled simulation model isdeveloped for the finite element analysis. ANSYS Maxwell package is used toobtain the magnetic field intensity, which is later converted to pressure usingan analytical equation, and this pressure is applied to the two-tube workingdomain in ANSYS Explicit Dynamics. Numerical simulations are done for differentcombinations of discharge energies and pitches of the thread to analysedeformation, stress and strain. The converged finite element results arevalidated using experimental data. The amount of deformation is found to beproportional to discharge energy and the pitch of the thread used. An empiricalrelation is developed for the deformation as a function of discharge energy andpitch. The relation is able to predict the deformation for other dischargeenergies, which is later verified with ANSYS simulations.

Electromagnetic Crimping on Threaded Surface: FEM Modelling, Validation  and Effects of Pitch and Discharge Energy on Deformation in an Empirical  Relation