Failure behavior in electrically-assisted mechanical clinching joints

Barimani-Varandi, Abozar; Aghchai, Abdolhossein Jalali; Lambiase, F.

doi:10.1016/j.jmapro.2021.06.072

Cited by 19 publications

(4 citation statements)

References 29 publications

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“…Neck fracture and pull-out modes, as the two most common failure modes [15,30,34], are also the two primary damaging forms of joint samples in this study, while another typical failure mode, named hybrid fracture [31], was observed only in the lap shear test of the RCB-2 joint. The occurrence of neck fracture and pull-out modes is mainly because of the unequal strength of the joint neck and undercut.…”

Section: Resultsmentioning

confidence: 89%

Joining three aluminium alloy sheets by square clinching process

Gao

Chen

2022

Materials Science and Technology

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The joining of three-layer AL5052-H32 sheets with the square and round clinching process was studied by experimental means. Two 1.5 mm thick and one 2 mm thick AL5052-H32 sheets with three sheet sequences were joined by the square and round clinching process, respectively. The results showed that the square tools can successfully join three sheets in all three sheet orders, while the round tools can effectively connect three sheets only when the thick sheet is at the bottom. Moreover, the strength of the round joints is generally lower than that of the square joints. The square three-layer joint with the thick top sheet achieves high strength at both two mechanical interlocks.

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Section: Resultsmentioning

confidence: 89%

Joining three aluminium alloy sheets by square clinching process

Gao

Chen

2022

Materials Science and Technology

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“…Additionally, the MMC criterion (Equation ( 10)) includes the parameters K and n, which represent the strain-hardening behavior, as well as three material constants denoted as C 1 , C 2 , and C 3 . While single-constant criteria may have fewer capabilities compared to multi-constant criteria, they are often preferred in designing manufacturing processes due to their simplicity [26][27][28]. Furthermore, each single-constant criterion can offer accurate results for a specific fracture mode.…”

Section: Ductile Fracture Modellingmentioning

confidence: 99%

Ductile Fracture Prediction in Hole Hemming of Aluminum and Magnesium Sheets

Kasaei,

Pereira,

Carbas

et al. 2023

Metals

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The present work proposes a suitable approach for predicting ductile fracture in a new joining process by plastic deformation called hole hemming. This process creates a combined form- and force-fit joint and enables the joining of lightweight materials with varying formability without requiring heating or auxiliary elements. In this process, the joinability of materials is limited by the occurrence of fracture in the outer sheet, highlighting the crucial need to accurately predict its damage during the process design phase. In this study, five different fracture criteria, including the McClintock, Rice–Tracey, Normalized Cockroft–Latham, and Brozzo and Modified Mohr–Coulomb (MMC) criteria, are examined during the joining of a challenging combination of lightweight materials (aluminum AA6082-T4 and magnesium AZ31). These criteria are calibrated by a hybrid experimental–numerical method using three tests with distinct stress states. These criteria are then implemented into the finite element model of the hole hemming process, utilizing an appropriate user subroutine. The results show that the flange edge of the outer sheet is the most prone region to fracture during the joining process, and a criterion must be able to model the fracture behavior of the material from uniaxial tension to shear to accurately predict fracture in this area. Among the examined criteria, only the MMC criterion was capable of such modeling and accurately predicted the critical displacement of the punch in the hemming stage with a negligible error (about 1%). On the other hand, the prediction accuracy of the other criteria varied significantly depending on the calibration test, resulting in errors ranging from 8.6% to 75.5%. The error of 8.6% was achieved with the Normalized Cockroft–Latham criterion calibrated by a uniaxial tension test. Thus, based on the results, the MMC criterion is recommended for ductile fracture prediction in the hole hemming process, offering valuable insights to assist in process design.

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“…Those points were the displacement points in which the measured and the calculated forces were compared and used in Eq. (1).…”

Section: Numerical Modelmentioning

confidence: 99%

“…The current trend in the automotive, aerospace, nautical and other similar industries is primarily a decrease in material consumption and indirectly a reduction in the mass of these means of transportation. In this respect, today, the so-called lightweight materials such as high-strength steel, aluminium, composite materials and the use of magnesium are increasingly emerging as construction materials [1] to [3]. However, due to the different properties of these materials their joining with the traditional welding process is not possible.…”

Section: Introductionmentioning

confidence: 99%

Incorporation of a Simplified Mechanical Joint Model into Numerical Analysis

Glavan¹,

Klemenc²,

Malnarič³

et al. 2022

sv-jme

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In the development of new joining technologies, incorporation of mechanical joints in computer analyses for the evaluation of structures can be carried out by a practical, simplified mechanical joint model. Here, two most frequently used joining technologies were analysed, a self-piercing rivet joint and a clinch joint. Physical tests of static load capacity of the joints were performed and numerical models for simulations were set-up. An optimization method was designed for estimating the material parameters of the mechanical joint for the needs of numerical analyses. For optimization purposes during the plan of experiments, a range of possible parameter values was investigated using a response surface method, results of simulations, results of physical tests and a genetic algorithm. The results of simulations using the optimal values of the material parameters are comparable to the experimental observations for the both joints.

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Failure behavior in electrically-assisted mechanical clinching joints

Cited by 19 publications

References 29 publications

Joining three aluminium alloy sheets by square clinching process

Joining three aluminium alloy sheets by square clinching process

Ductile Fracture Prediction in Hole Hemming of Aluminum and Magnesium Sheets

Incorporation of a Simplified Mechanical Joint Model into Numerical Analysis

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