Process Strategies and Analysis of Rolled‐in Tubes

A new method to manufacture composite workpieces is joining of two parts by rolling‐in, a technique which has been developed at the Department of Machining Technology (ISF) and at the Institute of Forming Technology and Lightweight Construction (IUL). In this article, the technology is described and different strategies to shorten the joining process without a decrease of the strength of the composite are presented and compared. To improve the knowledge about the material flow, the strain distribution in the contact zone has been analysed both experimentally and by means of finite element analyses (FEA). In order to evaluate the strength of the composite, an analysis of the press‐out forces and of the residual stresses in the inner tube has been carried out, also by means of experiments and simulations.