Abstract This paper focus on the production of hybrid busbars made from copper and aluminium by means of a joining by forming process that was recently developed by the authors. The process involves the combined use of partial cutting and bending with form-fit joining by compression in the direction perpendicular to strip thickness. The resulting joints are flat with the plastic deformed materials enclosed within the thickness of the overlapped strips. Design is performed by means of an analytical model and the overall manufacturing concept is validated through numerical and experimental modelling. Major process parameters are identified and their influence on the overall deformation mechanics and joining feasibility is investigated. The effectiveness and performance of the new joints is analysed by means of tensile-shear loading tests. Results show that joining by forming can be successfully utilized to produce form-fit joints with good shear forces in hybrid busbars for electrical applications.

中文翻译：

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通过成型连接制造混合母线

摘要 本文重点介绍了通过作者最近开发的成型工艺连接生产由铜和铝制成的混合母线。该工艺包括将部分切割和弯曲与通过在垂直于带钢厚度的方向上压缩的形状配合连接相结合。产生的接头是平坦的，塑性变形材料包含在重叠条带的厚度内。设计是通过分析模型进行的，整体制造概念通过数值和实验建模进行验证。确定了主要工艺参数，并研究了它们对整体变形力学和连接可行性的影响。新接头的有效性和性能通过拉伸剪切载荷试验进行分析。