Joining of a tube to a sheet through end curling

Abstract The motive of sustainable manufacturing is to develop manufacturing processes aiming at optimum use of resources without creating environmental pollution in any form, and reduce waste. In this context, the main objective of the present work is to propose a simple method of joining a tube to a sheet through end curling and to demonstrate the same at lab scale. For this purpose, a comprehensive computer aided engineering analyses using finite element simulations of the proposed method has been performed and the successfully formed joints are identified. Three different criteria are proposed for the quality analyses purpose. The influence of parameters on the forming behavior has been studied. Out of all the parameters, the die groove radius, friction conditions, and tube support length are found to be significant in deciding the quality of the joints. The criteria proposed are simple and can be implemented at the shop floor without measurements and calculations to assess the joint quality. The finite element simulations help in attaining the optimized cases for successful joint formation. Finally, the successful lab scale demonstration of the joining method indicates the suitability of the method for mass production with appropriate process design and planning.