The assembling elements that were formed bimetallic billet in T-shape were chosen for lap joints creating of workpieces from thin sheets of metallic (Fe-Fe, Fe-Al) as well as metallic – nonmetallic (Fe-PMMA, Al-PMMA) materials by Resistance Element Welding method (REW). The tubes of Cu 99.9 with dimensions 4 mm x 0.5 mm and a length of 11 mm filled with a brazing solder Sn60Pb40 were used for the elements producing. The required shape of elements is obtaining by the cold solid forming. Simulation by ANSYS software code was chosen for optimization of forming process and functional parts geometry of forming tool allowing to use only one extrusion forming operation. The simulations results are stresses, strains and modification of cross-section geometry of billets for three proposed forming modes. The functional parts geometry of tool was compared with the results of cross-section macroanalysis of billets made by laboratory tools. Also, REW joints of selected material combination that were subjected to macroanalysis were presented.Keywords: Extrusion, strain, simulation, REW, forming tool
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