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Finite Element Simulation of the Presta Joining Process for Assembled Camshafts: Application to Aluminum Shafts

1
Chair of Solid Mechanics, Institute of Mechanics and Thermodynamics, Chemnitz University of Technology, Reichenhainer Str. 70, D-09126 Chemnitz, Germany
2
Chair of Materials Science, Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Str. 73, D-09125 Chemnitz, Germany
*
Author to whom correspondence should be addressed.
Metals 2018, 8(2), 128; https://doi.org/10.3390/met8020128
Received: 22 December 2017 / Revised: 29 January 2018 / Accepted: 6 February 2018 / Published: 11 February 2018
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Abstract

This work shows a sequence of numerical models for the simulation of the Presta joining process: a well-established industrial process for manufacturing assembled camshafts. The operation is divided into two sub-steps: the rolling of the shaft to widen the cam seat and the joining of the cam onto the shaft. When manufactured, the connection is tested randomly by loading it with a static torque. Subsequently, there are three numerical models using the finite element method. Additionally, a material model of finite strain viscoplasticity with nonlinear kinematic hardening is used throughout the whole simulation process, which allows a realistic representation of the material behavior even for large deformations. In addition, it enables a transfer of the deformation history and of the internal stresses between different submodels. This work also shows the required parameter identification and the associated material tests. After comparing the numerical results with experimental studies of the manufacturing process for steel-steel connections, the models are used to extend the joining process to the utilization of aluminum shafts. View Full-Text
Keywords: numerical modeling; finite element method; large deformations; plasticity; aluminum; compression tests; torsion tests; shaft-hub connection; camshaft numerical modeling; finite element method; large deformations; plasticity; aluminum; compression tests; torsion tests; shaft-hub connection; camshaft
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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Scherzer, R.; Fritsch, S.; Landgraf, R.; Ihlemann, J.; Wagner, M.F.-X. Finite Element Simulation of the Presta Joining Process for Assembled Camshafts: Application to Aluminum Shafts. Metals 2018, 8, 128.

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