Al-Baradoni, N.; Heck, P.; Groche, P. High-Precision Integration of Optical Sensors into Metallic Tubes Using Rotary Swaging: Process Phenomena in Joint Formation. J. Manuf. Mater. Process.2024, 8, 60.
Al-Baradoni, N.; Heck, P.; Groche, P. High-Precision Integration of Optical Sensors into Metallic Tubes Using Rotary Swaging: Process Phenomena in Joint Formation. J. Manuf. Mater. Process. 2024, 8, 60.
Al-Baradoni, N.; Heck, P.; Groche, P. High-Precision Integration of Optical Sensors into Metallic Tubes Using Rotary Swaging: Process Phenomena in Joint Formation. J. Manuf. Mater. Process.2024, 8, 60.
Al-Baradoni, N.; Heck, P.; Groche, P. High-Precision Integration of Optical Sensors into Metallic Tubes Using Rotary Swaging: Process Phenomena in Joint Formation. J. Manuf. Mater. Process. 2024, 8, 60.
Abstract
A novel process design for damage-free and highly accurate positional integration of an optical multi-axial force sensor into a hollow tube by means of rotary swaging is introduced. Numerical simulations reveal relevant process phenomena of thin disc joining inside a pre-toothed hollow tube and help to find an optimal process design. Experimental trials show a significant effect of axial material flow and the number of tools in a rotary swaging process. By taking these effects into account, a successful form- and force-fit joining of the sensor carrying discs into the tube can be achieved. A successful joining of an optical sensor for bending forces and torque measurement shows hysteresis-free sensory behavior and thus backlash-free joining of the sensor carrier discs. The paper finishes with presenting an approach for closed-loop position controlling during the joining process and numerically investigation of the process design.
Keywords
sensory structure; joining by forming; high accurate joining by forming
Subject
Engineering, Mechanical Engineering
Copyright:
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.
