Project name: Joining by Forming of Hybrid Busbars for E-Mobility
Project code: Busbars - PTDC/EME-EME/0949/2020
Project timeline: 2021 - 2024
Research group: Manufacturing and Industrial Management
Objective
This project was designed to provide the following contributions to science and technology of materials processing. Firstly, to provide new joining by forming processes to produce hybrid busbars for electric vehicles and for electric applications, in general. Secondly, to obtain a clear understanding of the deformation mechanics of the new processes and of their workability limits and typical failure modes, by means of a combined theoretical and experimental investigation that will make use of finite element modelling and experimentation in flexible tool systems, to be designed and fabricated by the authors. Thirdly, to investigate which materials (copper or copper-aluminium) should be employed for obtaining the best electric and formability performances at a lower cost, and to compare the electric contact resistance of the new hybrid busbars produced by joining by forming against those produced by fastening or welding. Fourthly, to determine the pull-out, shear and fatigue strength of the hybrid busbars produced by joining by forming and by conventional fastening or welding. Fifthly, to move towards industrialization by producing hybrid busbars in collaboration with a Portuguese SME that fabricates automotive components.
Project team
Publications
Rui F.V. Sampaio, J. P. M. Pragana, I. M. F. Bragança, C.M.Alves Silva, Nielsen C.V,, P.A.F. Martins, On the utilization of radial extrusion to characterize fracture forming limits. Part II ? testing and modelling, SheMet 2023 - The 20th International Conference on Sheet Metal, Materials Research Proceedings , Apr, 2023
Rui F.V. Sampaio, J. P. M. Pragana, I. M. F. Bragança, C.M.Alves Silva, Nielsen C.V,, P.A.F. Martins, On the utilization of radial extrusion to characterize fracture forming limits. Part I ? methodology and tooling, SheMet 2023 - The 20th International Conference on Sheet Metal, Materials Research Proceedings , Apr, 2023
J. P. M. Pragana, Rui F.V. Sampaio, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, Joining by Forming of Busbars for Electric Energy Distribution Systems, MESIC2023 - 10th Manufacturing Engineering Society International Conference, Gijón, Spain, Jun, 2023
Rui F.V. Sampaio, J. P. M. Pragana, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, On the characterization of fracture forming limits for highly ductile metals through radial extrusion, ICTP 2023 - The14th International Conference on the Technology of Plasticity, Aug, 2023
J. P. M. Pragana, Rui F.V. Sampaio, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, An injection lap riveting tool system, ICTP 2023 - The14th International Conference on the Technology of Plasticity, Aug, 2023
Rui F.V. Sampaio, J. P. M. Pragana, I. M. F. Bragança, C.M.Alves Silva, Nielsen C.V,, P.A.F. Martins, Characterization of the Fracture Forming Limits in Bulk Forming by Means of Radial Extrusion, XLII SENAFOR, Porto Alegre, Brasil, Aug, 2023
Rui F.V. Sampaio, Larue P, J. P. M. Pragana, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, Double-Flush Riveting by Punching and Compression, Journal of Advanced Joining Processes, 8, 100155, 2023
Zwicker M.F.R., Spangenberg J., Bay N., P.A.F. Martins, Nielsen C.V,, The Influence of Hydrostatic Pressure Build-up on Asperity Flattening under Bulk Plastic Deformation, Journal of Materials Processing Technology, 315, 117919, 2023
J. P. M. Pragana, Rui F.V. Sampaio, J. Chantreuil, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, Double-Sided Injection Lap Riveting, International Journal of Advanced Manufacturing Technology, 125, 3241?3253, 2023
C.M.Alves Silva, Rui F.V. Sampaio, J. P. M. Pragana, I. M. F. Bragança, P.A.F. Martins, An Upset Geometry Sequence for Determining the Formability Limits in Bulk Forming, CIRP Annals ? Manufacturing Technology, 72, 255-258, 2023
Rui F.V. Sampaio, N.S.M. Alexandre, J. P. M. Pragana, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, A Software for Research and Education in Ductile Damage, Advances in Industrial and Manufacturing Engineering, 7, 100127, 2023
J. P. M. Pragana, Rui F.V. Sampaio, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, A Joining by Plastic Deformation Process to Fabricate Butt Joints in Copper-Aluminium Busbars, CIRP Journal of Manufacturing Science and Technology, 43, 205-213, 2023
Rui F.V. Sampaio, J. P. M. Pragana, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, Thermo-electrical performance of hybrid busbars: An experimental and numerical investigation, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 237, 1, 70-80, 2023
Sampaio R.F.V., J. P. M. Pragana, Clara R.G.., I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, New Self-Clinching Fasteners for Electric Conductive Connections, Journal of Manufacturing and Materials Processing, 6, 159, 2022
Lucas F. M. da Silva, P.A.F. Martins, Uwe Reisgen, Thomas Kannengießer, Advanced In-Situ Techniques, Forces in Mechanics, Jan, 2022
Meschut G., Merklein M., Brosius A., Drummer D., Fratini L., Füssel U., Gude M., Homberg W., P.A.F. Martins, Bobbert M., Lechner M., Kupfer R., Gröger B., Han D., Kalich J., Kappe F., Kuball C.-M., Popp J., Troschitz J., Römisch D., Wischer C., Wituschek S., Review on mechanical joining by plastic deformation, Journal of Advanced Joining Processes, 5, 100113, 2022
da Silva, L.F.M:, P.A.F. Martins, Reisgen U., Joining by Plastic Deformation, Journal of Materials: Design and Applications, 236, Jun, 2022
Nielsen C.V,, Zwicker M.F.R., Spangenberg J., Bay N., P.A.F. Martins, The Role of Entrapped Lubricant in Asperity Flattening under Bulk Plastic Deformation, CIRP Annals ? Manufacturing Technology, 71, 241-244, 2022
J. P. M. Pragana, Sampaio R.F.V., I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, Injection Lap Riveting of Aluminum Busbars – A Thermo-Electro-Mechanical Investigation, Journal of Manufacturing and Materials Processing, 6, 74, 2022
Sampaio R.F.V., J. P. M. Pragana, I. M. F. Bragança, Fernandes J.C.S., C.M.Alves Silva, P.A.F. Martins, Influence of Corrosion on the Electrical and Mechanical Performance of Hybrid Busbars, International Journal of Lightweight Materials and Manufacture, 5, 510-519, 2022
Rui F.V. Sampaio, J. P. M. Pragana, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, Thermoelectric performance of hybrid busbars: an experimental and numerical investigation, 4th International Conference on Materials Design and Applications, Porto, Portugal, Jul, 2022
Rui F.V. Sampaio, J. P. M. Pragana, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, Expanding the fracture limits of bulk metal forming to biaxial tension states, 5th Meeting of the Young Researchers of LAETA, Lisbon, Portugal, May, 2022
Chantreuil J., J. P. M. Pragana, Rui F.V. Sampaio, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, Millestone M2 – Hybrid busbars with invisible joints, Jun, 2022
J. P. M. Pragana, Rui F.V. Sampaio, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, Joining by forming of busbars for electric power distribution, SMF 2022 ? Conference on Recent Advances in Sheet Metal Forming, Pune, India, Nov, 2022
J. P. M. Pragana, Rui F.V. Sampaio, I. M. F. Bragança, C.M.Alves Silva, P.A.F. Martins, Innovative joining by Forming Production of Hybrid Busbars for Electric Power Distribution, Metal Forming 2022 ? The 19th International Conference on Metal Forming, Taiyuan, China, Sep, 2022