Elastomeric Swaging Finite Element Analysis Methodology to Evaluate Structural Integrity of Internal Swaged Joints 2024-26-0428

In applications demanding high performance under extreme conditions of pressure and temperature, a range of Mechanically Attached Fittings (MAFs) is offered by various Multinational Corporations (MNCs). These engineered fittings have been innovatively designed to meet the rigorous requirements of the aerospace industry, offering a cost-effective and lightweight alternative to traditional methods such as brazing, welding, or other mechanically attached tube joints. One prominent method employed for attaching these fittings to tubing is through Internal Swaging, a mechanical technique. This process involves the outward formation of rigid tubing into grooves within the fitting. One of the methods with which this intricate operation is achieved is by using a drawbolt - expander assembly within an elastomeric swaging machine. Traditionally, elastomeric swaged joints find extensive application among Aerospace Industry Original Equipment Manufacturers (OEMs) and are compatible with materials like Titanium, Aluminum, and Stainless Steel, accommodating various tube wall thicknesses. To optimize the design and manufacturing process, a Finite Element Analysis (FEA) methodology has been developed utilizing the licensable Abaqus software. This methodology simulates the intricate cold forming operation of elastomeric swaging, establishing a robust correlation between FEA and physical testing results. This correlation addresses critical quality parameters such as structural integrity and mechanical strength, aiding in the optimization of swaging parameters, minimizing testing requirements, and significantly reducing the overall lead time for the development of new swaged joints.