Process-induced bottom defects in clinch forming: Simulation and effect on the structural integrity of single shear lap specimens

Coppieters, Sam; Zhang, H.; Xu, Fan; Vandermeiren, N.; Breda, Andreas; Debruyne, Dimitri

doi:10.1016/j.matdes.2017.05.077

Cited by 43 publications

(35 citation statements)

References 32 publications

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“…For the geometrical analysis of a clinch element, photographs or micrographs of cross-sections are evaluated conventionally (cf. [ 9 , 24 , 25 ]). These methods have the disadvantage that the joining zone can only be evaluated in one section plane and thus three-dimensional phenomena, such as fibre reorientations, can hardly be evaluated.…”

Section: Materials and Methodsmentioning

confidence: 99%

Clinching of Thermoplastic Composites and Metals—A Comparison of Three Novel Joining Technologies

et al. 2021

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Clinching continuous fibre reinforced thermoplastic composites and metals is challenging due to the low ductility of the composite material. Therefore, a number of novel clinching technologies has been developed specifically for these material combinations. A systematic overview of these advanced clinching methods is given in the present paper. With a focus on process design, three selected clinching methods suitable for different joining tasks are described in detail. The clinching processes including equipment and tools, observed process phenomena and the resultant material structure are compared. Process phenomena during joining are explained in general and compared using computed tomography and micrograph images for each process. In addition the load bearing behaviour and the corresponding failure mechanisms are investigated by means of single-lap shear tests. Finally, the new joining technologies are discussed regarding application relevant criteria.

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Section: Materials and Methodsmentioning

confidence: 99%

Clinching of Thermoplastic Composites and Metals—A Comparison of Three Novel Joining Technologies

et al. 2021

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“…Reducing the embossment thickness increases the joint strength; however, it is connected with increasing the forming force. Coppieters et al [11] studied the bottom defects that were generated while creating the permanent interlock in the case of clinching with a rigid die. The study shows that the observed bottom cracks can be predicted by means of the axisymmetric FE model while using the modified Rousselier model.…”

Section: Introductionmentioning

confidence: 99%

Designing and Testing Cold-Formed Rounded Connections Made on a Prototype Station

Rejek¹,

Wróbel²,

Królczyk

et al. 2019

Materials

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This paper presents the design of cold-formed rounded connections between a tube and a connecting block and the analysis of test results that were carried out with six fabricated samples. The joints manufactured on a specially designed prototype station were made by forming tools that were adjusted to connecting elements regarding the diameter and the shape. All of the samples prepared for this study were of the same diameters relating to the diameter of a hole in a connecting block and the outer diameter of a pipe flange. However, they were different concerning the height of the connecting block flange. The article presents features of joints that were manufactured with a designed forming tool on the prototype station. The achieved connections were examined in destructive testing (Micrography, Tensile Strength Test) and in non-destructive testing (Leakage Test). The research project aims were to state the differences in energy consumption of made connections and extend the concept of cold-formed rounded connections. Furthermore, this article presents the effects of FEA simulation of the cold-formed joint based on the results of destructive and non-destructive tests.

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“…This modified damage model can describe the evolution of the fracture with the initial void volume fraction and the shear damage parameter. Coppieters et al [ 15 ] used a modified Rousselier damage model [ 14 ] to describe the fracture behavior in the bottom of the clinched joint under overload. Lambiase and Di Ilio [ 16 ] explored a numerical model that describes the evolution of ductile damage in predicting the onset of fracture during the clinch joining of thin aluminum AA6082-T6 sheets.…”

Section: Introductionmentioning

confidence: 99%

Optimized Calibration Procedure of the Damage Parameters of AA6082-T6 Sheets

Zhang

Zhao

et al. 2018

Materials

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The constitutive equation of AA6082-T6 sheets is investigated by an extended Rousselier damage model. Previous research is mainly comprised of single-pull test specimens, notched tensile specimens, tensile specimens with a hole, and shear specimens. To decrease the natural material errors, a new specimen is used. In this paper, a clinched joint is regarded as a specimen to calibrate the initial void volume fraction kω and the shear damage parameter f0 by using the orthogonal analysis method, which can reduce the simulation times and accuracy. It also reveals that the initial void volume fraction f0 affects the void volume fraction in the neck and the groove of the clinched joint, and the shear damage parameter kω affects just the void volume fraction f in the neck of the clinched joint. It checks the force-displacement curve, shape of the clinched joint, and the fracture location, and approves that these damage parameters can describe the deformation process, fracture location, and shape of the clinched joint.

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Process-induced bottom defects in clinch forming: Simulation and effect on the structural integrity of single shear lap specimens

Cited by 43 publications

References 32 publications

Clinching of Thermoplastic Composites and Metals—A Comparison of Three Novel Joining Technologies

Clinching of Thermoplastic Composites and Metals—A Comparison of Three Novel Joining Technologies

Designing and Testing Cold-Formed Rounded Connections Made on a Prototype Station

Optimized Calibration Procedure of the Damage Parameters of AA6082-T6 Sheets

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