Testing and modelling of flow-drill screw connections under quasi-static loadings

Abstract

The behaviour of a flow-drill screw connection under different quasi-static loadings was simulated using finite element models with detailed solid element meshes. The numerical models were developed with a rateindependent isotropic hypoelastic-plastic material model. A process-effect analysis was conducted, including investigation of the microstructure as well as hardness tests. Based on the investigation, the process effects were considered negligible. A simple approach for building up the geometry of the connection was presented. An experimental programme consisting of five different single-connector tests was carried out to characterise the connection, and was presented in detail. Each test was simulated, allowing for one-to-one comparisons between tests and simulations. Satisfactory results were achieved.

Direct bolting of railway aluminium vehicle components with flow drill screwing

“…A technically smarter and highly economical solution is direct bolting by flow drill screwing (FDS). Figure 1 shows the FDS procedure according to [1].…”

“…Figure 1: Procedure of flow drill screwing (FDS) acc. to [1] The FDS technology is well known in automotive industry, prioritizing joining of extruded aluminium profiles and higher strength steels [2,3,4]. In respect to the sheet metal thicknesses und strengths, FDS is also applicable with the aluminium alloys in railway wagon bodies.…”