A joining method for shaft part and holed part using plastic deformation was proposed. In this method, the shaft having lower deformation resistance is extruded into the holed part with having higher deformation resistance. The wall of the hole had inclination angles along the axial direction. For the verification, the holed part of S45C (in JIS) with uniform internal diameter and various average roughness's ranging from around 1 to 11 micrometers by lathe turning process were first joined to the outer surface of an A1200 (in JIS) aluminum shaft part. The flat punch was used here. As a result, the material of shaft was adequately fulfilled in the inner surface of the pipe. Second, the joining of the holed part of S45C with inclination angle and the shaft of A1200 was investigated. The punch with the flat head and four different impressions was used here. As a result, the thinner end of the holed part was curled inward and intruded into the shaft material as the extrusion proceeded. The good coincide of the extrusion load for joining between in experiment and calculation by FEM was obtained. Furthermore, the deformation behavior of the holed part was successfully reproduced by the calculation. The joining efficiency by the proposed method was around 69% at maximum for the tensile strength of A1200.
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