Determination of material distribution in heading process of small bimetallic bar

Wojciech Presz , Robert Cacko


The electrical connectors mostly have silver contacts joined by riveting. In order to reduce costs, the core of the contact rivet can be replaced with cheaper material, e.g. copper. There is a wide range of commercially available bimetallic (silver-copper) rivets on the market for the production of contacts. Following that, new conditions in the riveting process are created because the bi-metal object is riveted. In the analyzed example, it is a small size object, which can be placed on the border of microforming. Based on the FEM modeling of the load process of bimetallic rivets with different material distributions, the desired distribution was chosen and the choice was justified. Possible material distributions were parameterized with two parameters referring to desirable distribution characteristics. The parameter: Coefficient of Mutual Interactions of Plastic Deformations and the method of its determination have been proposed. The parameter is determined based of two-parameter stress-strain curves and is a function of these parameters and the range of equivalent strains occurring in the analyzed process. The proposed method was used for the upsetting process of the bimetallic head of the electrical contact. A nomogram was established to predict the distribution of materials in the head of the rivet and the appropriate selection of a pair of materials to achieve the desired distribution.
Author Wojciech Presz (FPE / IoMP)
Wojciech Presz,,
- The Institute of Manufacturing Processes
, Robert Cacko (FPE / IoMP)
Robert Cacko,,
- The Institute of Manufacturing Processes
Pages050014-1 - 050014-6
Book Presz Wojciech, Cacko Robert (eds.): 21st International ESAFORM Conference on Material Forming, vol. 1960, 2018
Keywords in Englishmicro-forming, bi-metallic connector, micro-riveting, numerical modeling
Languageen angielski
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