Clinching of Heated Aluminum Die Casting

Yarcu, S.; Huebner, S.R.; Yilkiran, Deniz; Brunotte, Kai; Behrens, Bernd‐Arno; Schuchardt, Torsten; Mueller, Soeren; Dilger, Klaus

doi:10.1007/978-3-030-78424-9_10

Cited by 2 publications

(1 citation statement)

References 7 publications

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“…Many studies have investigated optimization of this process, while neglecting joint quality [ 21 , 22 , 23 , 24 ]. However, there are few studies on the effect of deviations and tolerances of parameters on the clinching process.…”

Section: Introductionmentioning

confidence: 99%

Multiscale Analogue Modelling of Clinching Process to Investigate Thickness Tolerance and Tool Misalignment

et al. 2022

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NEED—The effect of dimensional variability of sheet thickness (tolerance) and tool misalignment is poorly understood for the clinching process. Finite element analysis (FEA) is valuable but requires a lot of and is difficult to verify in this situation due to the asymmetrical geometry and nonlinear plasticity. OBJECTIVE—The objective of this work was to determine the effect of thickness tolerance, tool misalignment and sheet placement (top vs. bottom) in the clinching process, by use of analogue modelling with plasticine. METHOD—Experiments used a scaled-up punch and die, with plasticine as the analogue. Thickness tolerances were represented by sheet thicknesses of 11 and 7 mm, 12 and 8 mm, 8 and 12 mm and 13 and 9 mm for upper and lower sheets, respectively. Two types of lubricant were tested between sheets: glycerine and silicone oil. Angular variability was also introduced. Measured parameters were interlock (also called undercut) and neck thickness. Analogue results for deformation were compared with microscopy of metal clinching. FINDINGS—The results reveal that the multiscale analogue model is an efficient tool for studying the effect of dimensional deviation on a clinch joint. Thickness tolerance showed a critical relationship with interlock, namely a reduction to about half that of the nominal, for both maximum and least material conditions. Increased angular misalignment also reduced the interlock. Compared with glycerine, silicone oil tests showed reduced interlock, possibly the result of a lower coefficient of friction. ORIGINALITY—This work demonstrates the usefulness of analogue modelling for exploring process variability in clinching. The results also show that significant effects for sheet placement are ductility, lubricant (friction), thickness of samples and tool misalignment.

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Section: Introductionmentioning

confidence: 99%

Multiscale Analogue Modelling of Clinching Process to Investigate Thickness Tolerance and Tool Misalignment

et al. 2022

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Clinching of inductively heated aluminum die casting

Yarcu

Behrens

Huebner

et al. 2022

Prod. Eng. Res. Devel.

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The aim of the investigations described in this article is to improve the clinching of aluminum die casting. The focus is on clinching an aluminum die casting alloy by local heat treatment and hence to join them in a process-safe manner. For this purpose, a heating strategy is used to warm up the die casting alloys to reduce temporarily and reversibly the elongation and the yield strength in the material. In preliminary investigations, three different heating strategies (heating plate, resistance heating and inductive heating) have been investigated. Induction heating has been selected as the most suitable method due to the short heating time and the production of crack-free clinch points. In this paper, two clinching tool systems (one with a flexible die, one with a rigid die) were used. For these tools, two inductors with different diameter were manufactured. The effects of each inductor and clinching tool on an aluminum die casting alloy, such as heating time and crack behavior, were investigated. Surface images of the clinch points in regard to the heat treatment temperature were analyzed. Furthermore, the characteristic parameters of the joints such as interlock, bottom thickness and neck thickness were examined. In addition, the strength of the joined parts was investigated by head tension tests. The results of the developed method showed that it is possible to produce crack-free clinching joints below 6 s. Furthermore, the local heating led to an increasing interlock resulting in a 26% increase of the head tensile strength.

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Clinching of Heated Aluminum Die Casting

Cited by 2 publications

References 7 publications

Multiscale Analogue Modelling of Clinching Process to Investigate Thickness Tolerance and Tool Misalignment

Multiscale Analogue Modelling of Clinching Process to Investigate Thickness Tolerance and Tool Misalignment

Clinching of inductively heated aluminum die casting

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