This paper showcases the capabilities of Abaqus explicit solver to simulate and solve problems involving huge plastic deformation due to caulking process. Caulking is a mechanical joining process achieved by plastically deforming a material in order to hold another material. This method is in research phase and being examined by engineers at Daimler and University of Erlangen-Nuremberg (Germany). This technique is mainly used in Permanent Magnet motors to hold the magnets in the rotor stacks. The objective of the simulation is to find optimum tool geometry, depth of tool penetration and location of penetration for caulking process. The process involves huge plastic deformation and is successfully simulated using Abaqus Explicit. This illustrates the effectiveness of numerical simulations, helping the designers in reducing the need for actual test bench with numerous high cost fabricated hardware setup and thereby saving huge R &D cost and time.
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