This paper presents a deformation assisted joining process for fixing a sheet to a rod away from the rod ends, at room temperature. The process requires machining a rectangular cross-section slot in the rod so that material from the sheet can be locally indented and injected into the slot to produce a form-fit joint. Selected examples retrieved from experimentation and finite element simulation allow understanding the overall deformation mechanics, identifying the major operating parameters, and establishing design guidelines for both punches and slots. Detailed information on the punch strokes and geometries to obtain sheet-rod connections with an adequate filling of the slots and without excessive reduction of the cross-sectional shear length are provided. The new proposed process was built upon modification of an earlier development for fixing thick hubs to shafts (or, rods) and is aimed at satisfying the challenges and requirements posed by thin sheets. Emphasis is placed on lowering the forming forces and facilitating injection and filling of the slots so that thin sheets can effectively be fixed to rods. Pull-out destructive tests performed on sheet-rod connections away from the rod ends confirm the good performance of the form-fit joints produced by the new proposed process.

本文提出了一种在室温下将片材固定在远离杆端的杆上的变形辅助连接方法。该方法需要在杆上加工一个矩形的横截面狭缝，以便可以将板材的材料局部压入并注入到狭缝中以形成形状配合接头。从实验和有限元模拟中选取的示例可以帮助您了解整体变形机理，识别主要操作参数以及为冲头和槽口建立设计准则。提供了有关冲头行程和几何形状的详细信息，以获得具有足够填充缝隙且不会过度减小横截面剪切长度的薄板-杆连接。新提议的工艺建立在对较早的开发进行修改的基础上，该工艺将较厚的轮毂固定到轴（或杆）上，旨在满足薄板带来的挑战和要求。重点是降低成形力并促进缝隙的注入和填充，以便可以将薄板有效地固定到棒上。在远离杆端的薄板-杆连接上进行的拉拔破坏性测试证实了新工艺所产生的形状配合接头的良好性能。