Fundamentals of Angular Joining by Means of Hydroforming

A process strategy to join hollow workpieces angularly and to shape them simultaneously is presented. The main focus is joining without welding, which is realized with a fluid-based force fit. A T-shaped model is used to verify the strategy numerically and experimentally. The key to successful joining lies in a process phase, in which accumulated material is compressed. This causes the workpieces to expand and to deflect elastically in order to create a force fit. A load analysis shows that the joined structure bears static and dynamic loads of practical relevance.