A Novel Method for Joining Steel/Al Tube Parts Based on Electromagnetic Force by Flat Coil
Round 1
Reviewer 1 Report
The presented article describes the research on a new method of shape joining cylindrical elements (pipes) subjected to torsional loads.
In my opinion, the presented scope of analyzes is too narrow. The very description of the deformation process in the scope of the connections made is extensive, but the general approach to the problem is too narrow. There is no reference (comparison) to similar connections but made by crimping. There is no reference to the performance of the proposed joining method with respect to other methods (plastic deformation). The scope of variables in the experiment is narrow because it only concerns the energy of the discharges in three ranges. There is no evaluation of the influence of other parameters, such as the geometry of the joint groove. The edge of the groove itself could be modified to prevent shearing of the deformed joint zone of the outer pipe, etc.
Author Response
Detailed Response to Reviewer 1
Honorable reviewer:
On behalf of my co-authors, we thank you very much for giving us an opportunity to revise our manuscript. We appreciate you very much for your positive and constructive comments and suggestions on our manuscript entitled “A novel method for joining steel/Al tube parts based on electromagnetic force by flat coil” (ID: coatings-1403891). We have studied your comments carefully and have made revisions which marked in red in the paper. We have tried our best to revise our manuscript according to the comments. Attached please find the revised version, which we would like to submit for your kind consideration. Looking forward to hearing from you.
Our responses to reviews’ comments and suggestions present as follows.
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Comments and Response:
Reviewer #1
The presented article describes the research on a new method of shape joining cylindrical elements (pipes) subjected to torsional loads.
In my opinion, the presented scope of analyzes is too narrow. The very description of the deformation process in the scope of the connections made is extensive, but the general approach to the problem is too narrow. There is no reference (comparison) to similar connections but made by crimping. There is no reference to the performance of the proposed joining method with respect to other methods (plastic deformation). The scope of variables in the experiment is narrow because it only concerns the energy of the discharges in three ranges. There is no evaluation of the influence of other parameters, such as the geometry of the joint groove. The edge of the groove itself could be modified to prevent shearing of the deformed joint zone of the outer pipe, etc.
Response: We appreciate the reviewer’s comment. This paper presents a method for joining large diameter pipe fittings by flat coil. In the past, electromagnetic crimping was done through a cylindrical collector. The method proposed in this study significantly improves its flexibility. As for the mechanical properties, when the discharge voltage is above 14kJ, the joint failure occurs in the base metal. It means the joint is stronger than the base metal. It can also be seen from the torque force-angle curve that there is little difference between the mechanical properties of the joints with 14 and 16 kJ. Therefore, the mechanical properties of the joint is no longer improved by modifying the geometry of the groove. The joint has reached the desired strength and there is no need to compare it with other processes.
Reviewer 2 Report
The paper is written according to the requirements for publication and meets all criteria.
- the paper is written in compliance with the requirements regarding the description of methodology developed in the research activity;
- from the aspect of writing it can be mentioned that the text is easy to read and understand and the table and figures are written in unitary format with details that ensure a correct identification of the content (the text used in figures is legible and the drawings / photographs presented are designed in appropriate dimensions);
- the abstract is adequate to the content of the article;
- the conclusions are formulated adequately with the results of the presented researches.
Some minor corrections for English style are needed but not compulsory.
Author Response
Detailed Response to Reviewer 2
Honorable reviewer:
On behalf of my co-authors, we thank you very much for giving us an opportunity to revise our manuscript. We appreciate you very much for your positive and constructive comments and suggestions on our manuscript entitled “A novel method for joining steel/Al tube parts based on electromagnetic force by flat coil” (ID: coatings-1403891), We have studied your comments carefully and have made revisions which marked in red in the paper. We have tried our best to revise our manuscript according to the comments. Attached please find the revised version, which we would like to submit for your kind consideration. Looking forward to hearing from you.
Our responses to reviews’ comments and suggestions present as follows.
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Comments and Response:
Reviewer #2
The paper is written according to the requirements for publication and meets all criteria.
-the paper is written in compliance with the requirements regarding the description of methodology developed in the research activity;
-from the aspect of writing it can be mentioned that the text is easy to read and understand and the table and figures are written in unitary format with details that ensure a correct identification of the content (the text used in figures is legible and the drawings/photographs presented are designed in appropriate dimensions);
- the abstract is adequate to the content of the article;
- the conclusions are formulated adequately with the results of the presented researches.
Some minor corrections for English style are needed but not compulsory.
Response: We appreciate the reviewer’s kindly comment. Thank you for your recognition. As for the English style, we have read it carefully several times and modified it accordingly.
Please see line 1 in paragraph 2 on page 2. As follows:
Joining processes based on plastic deformation of at least one joining part promised great potential regarding the production of multi-material joints.
Please see line 6-7 in paragraph 1 on page 13. As follows:
As for the reason why position G was located on the edge of the coil, it was because without a mandrel supporting inside the outer tube.
Reviewer 3 Report
In the manuscript, an interesting, relatively cheap and effective technique for joining of different materials was introduced, which could be beneficial for the automotive industry. The text has a good structure, it is clear to read and it seems to be an original. The used techniques are simple but appropriated and the results are sufficiently discussed. The readers can obtain useful information in the field.
I recommend just minor amendments, which are mostly typo corrections.
- Page1 and further:
- Please, avoid to use the phrase “joining partner”, instead of this use for instance “joining material” or “joining part”.
- Page 2:
- Correct “magnetic pluse welding” by “ magnetic pulse welding”.
- The physical quantities write with using italics and lower indexes for inner resistance Ri, inner inductance Li and capacitance C.
- Page 3:
- “The Setup” should be with small “s”.
- Correct “angel” by “angle”.
- Page 4:
- Correct the commas in “(position A, B, C, D, E, F, G)”.
- Page 5:
- Correct the physical unit Newton-meter “N M” by “N.m”.
- Page 7:
- Please, add a scale into the Fig. 7 and 8.
- Page 8, 9:
- Something is wrong in the sentence “As for the reason why position G be located on the edge of the coil, it is because without a mandrel supporting inside the outer tube”. Maybe “position G is/was located”?
- The photos in the Fig. 9 on the top left hand side are too small, please magnify them. The same for Fig. 11.
- Page 10:
- Please, add a space between the name and the unit on Y-axis of Fig. 12.
- Page 13:
- Cite the references according to the requirements of the journal. The year of paper should be bold.
The manuscript can be after suggested minor revision accepted for publication in your journal.
Author Response
Detailed Response to Reviewer 3
Honorable reviewer:
On behalf of my co-authors, we thank you very much for giving us an opportunity to revise our manuscript. We appreciate you very much for your positive and constructive comments and suggestions on our manuscript entitled “A novel method for joining steel/Al tube parts based on electromagnetic force by flat coil” (ID: coatings-1403891). We have studied your comments carefully and have made revisions which marked in red in the paper. We have tried our best to revise our manuscript according to the comments. Attached please find the revised version, which we would like to submit for your kind consideration. Looking forward to hearing from you.
Our responses to reviews’ comments and suggestions present as follows.
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Comments and Response:
Reviewer #3
In the manuscript, an interesting, relatively cheap and effective technique for joining of different materials was introduced, which could be beneficial for the automotive industry. The text has a good structure, it is clear to read and it seems to be an original. The used techniques are simple but appropriated and the results are sufficiently discussed. The readers can obtain useful information in the field.
I recommend just minor amendments, which are mostly typo corrections.
Page1 and further:
Please, avoid to use the phrase “joining partner”, instead of this use for instance “joining material” or “joining part”.
Page 2:
Correct “magnetic pluse welding” by “ magnetic pulse welding”.
The physical quantities write with using italics and lower indexes for inner resistance Ri, inner inductance Li and capacitance C.
Page 3:
“The Setup” should be with small “s”.
Correct “angel” by “angle”.
Page 4:
Correct the commas in “(position A, B, C, D, E, F, G)”.
Page 5:
Correct the physical unit Newton-meter “N M” by “N.m”.
Page 7:
Please, add a scale into the Fig. 7 and 8.
Page 8, 9:
Something is wrong in the sentence “As for the reason why position G be located on the edge of the coil, it is because without a mandrel supporting inside the outer tube”. Maybe “position G is/was located”?
The photos in the Fig. 9 on the top left hand side are too small, please magnify them. The same for Fig. 11.
Page 10:
Please, add a space between the name and the unit on Y-axis of Fig. 12.
Page 13:
Cite the references according to the requirements of the journal. The year of paper should be bold.
The manuscript can be after suggested minor revision accepted for publication in your journal.
Response: We appreciate the reviewer’s kindly comment. Thanks for pointing out these errors. According to the reviewer’s suggestion, we have modified the above errors.
Please see line 1 in paragraph 2 on page 2. As follows:
Joining processes based on plastic deformation of at least one joining part promised great potential regarding the production of multi-material joints.
Please see line 3-7 in paragraph 2 on page 3. As follows:
Magnetic pulse welding (MPW), as it is known, is one of the case. The typical setup of MPW consisting of the EMF machine, the tool coil, and the workpiece. This setup can be represented by a RLC circuit in which the forming machine is symbolized by the inner resistance Ri, the inner inductance Li and the capacitance C.
Please see line 3-4 in paragraph 3 on page 3. As follows:
For the manufacturing of crimping connections, the material of one joining part is formed into an undercut of the other partner.
Please see line 1 in paragraph 1 on page 8. As follows:
Fig. 4 shows the position of the microscopic observation, the connection area was divided into 7 positions in average in the x-axis direction（position A, B, C, D, E, F, G), then each position was cut away by wire cutting.
Please see line 1 in paragraph 1 on page 9. As follows:
When the torsion angle was about 15°, the torsion force of the joint with 12 kJ reached its peak (about 1200 N.m).
Please see line 6-7 in paragraph 1 on page 13. As follows:
As for the reason why position G was located on the edge of the coil, it was because without a mandrel supporting inside the outer tube.
Reviewer 4 Report
This paper presented joining of tubes by electromagnetic crimping. A wide range of literature was introduced to justify the need for this research. The experimental section is clearly described which makes the research reproducible. It was concluded that suitable joint can be produced by this joining method and the optimized joining condition achieved for 14 kJ power. The conclusion was drawn based on experimental result and the manuscript deserve to be published. The followings are few minor comments:
Figure 2: In the caption please mention that the dimensions are in mm.
Include a scale bar in figure 3.
Author Response
Detailed Response to Reviewer 4
Honorable reviewer:
On behalf of my co-authors, we thank you very much for giving us an opportunity to revise our manuscript. We appreciate you very much for your positive and constructive comments and suggestions on our manuscript entitled “A novel method for joining steel/Al tube parts based on electromagnetic force by flat coil” (ID: coatings-1403891). We have studied your comments carefully and have made revisions which marked in red in the paper. We have tried our best to revise our manuscript according to the comments. Attached please find the revised version, which we would like to submit for your kind consideration. Looking forward to hearing from you.
Our responses to reviews’ comments and suggestions present as follows.
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Comments and Response:
Reviewer #4
This paper presented joining of tubes by electromagnetic crimping. A wide range of literature was introduced to justify the need for this research. The experimental section is clearly described which makes the research reproducible. It was concluded that suitable joint can be produced by this joining method and the optimized joining condition achieved for 14 kJ power. The conclusion was drawn based on experimental result and the manuscript deserve to be published. The followings are few minor comments:
Q1: Figure 2: In the caption please mention that the dimensions are in mm.
Response: Thanks for pointing out this error. In the revised manuscript, we have mentioned that the dimensions are in mm in the caption of figure 2.
Please see Fig. 2 on page 6. As follows:
Fig. 2 Setup for electromagnetic crimping and the size of specimens (dimensions in mm).
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Q2: Include a scale bar in figure 3.
Response: Thanks for the comment. In the revised manuscript, we have added the scale bar in figure 3.
Round 2
Reviewer 1 Report
I understand the authors' statement regarding the achievement of the assumed load capacity by the joint, which exceeds the stability of the materials being joined. However, the lack of a broader reference, for example, to other types of shape joining in relation to the proposed one, results in an incomplete reception of the presented research scope.
Proposes to refer to specific data (not just publication references), eg in terms of method performance or the limitations of currently used methods in relation to the proposed one.
Author Response
Honorable reviewer:
On behalf of my co-authors, we thank you very much for giving us an opportunity to revise our manuscript again. We appreciate you very much for your positive and constructive comments and suggestions on our manuscript entitled “A novel method for joining steel/Al tube parts based on electromagnetic force by flat coil” (ID: coatings-1403891R1). We have studied your comments carefully and have made revisions which marked in red in the paper. We have tried our best to revise our manuscript according to the comments. Attached please find the revised version, which we would like to submit for your kind consideration. Looking forward to hearing from you.
Our responses to reviews’ comments and suggestions present as follows.
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Comments and Response:
Reviewer #1
I understand the authors' statement regarding the achievement of the assumed load capacity by the joint, which exceeds the stability of the materials being joined. However, the lack of a broader reference, for example, to other types of shape joining in relation to the proposed one, results in an incomplete reception of the presented research scope. Proposes to refer to specific data (not just publication references), e.g. in terms of method performance or the limitations of currently used methods in relation to the proposed one.
Response: Thanks for the suggestion. We appreciate the reviewer’s comment. In the revised manuscript, we have restated how this method differs from the others. Firstly, the previous electromagnetic crimping method for pipe fittings is to use circular magnetic collector [1, 2]. Moreover, a magnetic collector of one diameter can only connect pipe fittings of the corresponding diameter [3]. Therefore, the authors want to propose a method to connect pipe fittings of different diameters without changing the coil (magnetic collector). In this study, the main purpose is to propose a novel method for connecting large diameter pipe fittings with flat coil through electromagnetic force. Compared with the previous electromagnetic crimping method, the biggest innovation is that it does not require replacement of coil for joining tubes with different diameters. Moreover, through the verification of this study, the joint failure on the base metal, indicating that the strength can reach the expected target. In addition, as for the groove shape design proposed by reviewers, it is indeed a very worthy of study. In this study, the method is proposed and verified by torsion test. In the future, we will design the size of the groove according to the tensile and fatigue properties.
[1] Park, Y.B.; Kim, H.Y.; Oh, S.I. Design of axial/torque joint made by electromagnetic forming. Thin-walled structures. 2005, 43(5), 826–844.
[2] Weddeling, C.; Woodward, S.T.; Marr, M.; Nellesen, J.; Psyk, V.; Tekkaya, A.E.; Tillmann, W. Influence of groove characteristics on strength of form-fit joints. Journal of Materials Processing Technology. 2011, 211, 925–935.
[3] Ashish K.R.; Sachin D.K. Comparison of different types of coil in Electromagnetic terminal - wire crimping process: Numerical and experimental analysis. Journal of Manufacturing Processes. 2018, 34, 329-338.
Please see line 20-25 in paragraph 1 on page 4. As follows:
The studies of electromagnetic crimping mentioned above mainly used the typical setup of tube compression processes, and most of current investigations and publications dealing with crimped joints focused on the groove dimensions. However, the present electromagnetic crimping method for pipe fittings is to use circular magnetic collector. A magnetic collector of one diameter can only connect pipe fittings of the corresponding diameter. This kind of electromagnetic crimping requires replacement of magnetic collectors when joining the tubes with different diameters, and the cost is high. Therefore, a novel method is proposed to connect pipe fittings of different diameters without changing the coil.
