Electromagnetic crimping is a high-velocity joining method to join highly conductive workpieces where a pulsed magnetic field is applied without any working medium or mechanical contact to deform the workpiece. This work explores tube-to-tube joining of Copper outer tube and Stainless steel threaded inner tube using electromagnetic crimping. A non-coupled simulation model is developed for the finite element analysis. ANSYS Maxwell package is used to obtain the magnetic field intensity, which is later converted to pressure using an analytical equation, and this pressure is applied to the two-tube working domain in ANSYS Explicit Dynamics. Numerical simulations are done for different combinations of discharge energies and pitches of the thread to analyse deformation, stress and strain. The converged finite element results are validated using experimental data. The amount of deformation is found to be proportional to discharge energy and the pitch of the thread used. An empirical relation is developed for the deformation as a function of discharge energy and pitch. The relation is able to predict the deformation for other discharge energies, which is later verified with ANSYS simulations.
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