A new technology for the joining by forming of magnesium alloys

The current lightweight design is realized by the multi-material mix in body-in-white production of automotive industry. In car bodies, the proportion of high-strength steels and aluminum alloys increases. Therefore, it is necessary to join these materials. Mechanical joining processes are suitable for a multi-material mix. But in combination with high-strength steels, only processes with additional elements, like rivets, are useful. The development of a new clinching technology shows a solution for an economical method for joining these different materials. An innovative single-stage process without any additional joining elements is created to extend the current limits of mechanical joining technologies. This makes it possible to join aluminium alloys and high-strength steel by punching and clinching in one step. Using the special material behavior of the parts to be joined is most important for this mechanical joining process. A clinching sequence, a scheme and a gradual analysis support the understanding of this joining method. Some examples of connected material combinations complete this description. Further steps to improve this joining process are shown. Especially the finite element analysis will provide more process details for improving this innovative joining technology.

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“…Therefore, simulation with finite-element analysis especially reduces costs and time input for development processes. [5,6] …”

Section: Discussionmentioning

confidence: 99%

Development of a mechanical joining process for automotive body-in-white production

et al. 2010

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“…In this case, mechanical clinching is often the preferred joining technique for materials that are difficult to weld. 18–25 The hybrid clinching that combines a variety of joining methods, such as bond-clinching, ultrasound-assisted clinching, laser-assisted clinching, rivet-clinching, has been extensively researched, expanding the application field of mechanical clinching. 26–30 However, most of the existing clinching processes employed round punches.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation on the mechanical square clinching process for joining Al5052 sheets

Gao

Chen

Ren

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Clinching technology has been extensively applied as a green and clean joining method, which has the benefits of less energy consumption, no pollution and no noise. However, a single joint produced by round tools cannot withstand the torsion force. In order to solve this problem, a square clinching technology was proposed and investigated in this paper. The main geometric parameters, failure mode, static strength, and energy absorption of the square clinched joint were studied. The fracture characteristics of square clinched joints under different mechanical experiments were studied by a scanning electron microscope. The strength tests of Al5052 clinched joints under various forming forces were carried out. The results showed that the neck fracture mode was the only failure mode observed during the failure process. The microscopic morphology of the joint fracture shows typical ductile fracture characteristics. It turned out that the square clinching process can effectively join aluminum alloy sheets.

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“…Neugebauer et al [23] proposed a type of clinching process called dieless clinching to join magnesium alloy. The dieless clinching is similar to the flat clinching process to some degree for the reason that both processes adopt a flat anvil instead of a contoured die.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation of the novel dieless clinching process free of blank holder

Qin

Chen

Zhang

et al. 2021

Archiv.Civ.Mech.Eng

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A novel dieless clinching process free of blank holder was proposed in this study. This novel clinching process applied to joining Al5052 sheets under the forming forces from 24 to 54 kN was investigated experimentally. The joint geometrical characteristics, static mechanical strength, energy absorption and failure modes were revealed. From the results, the sound joints can be produced under various forming forces from 24 to 54 kN. With the forming force increasing, the neck thickness was increased continually while the interlock value remained almost constant. On the other hand, the protrusion height of clinched joint was reduced continually with the forming force increasing. Both the tensile strength and shear strength were enhanced with the forming force increasing. Under the forming force of 54 kN, the tensile strength and the shear strength were 1249 and 1107 kN, respectively. In general, a larger joining force leads to a better clinched joint with lower protrusion height and higher mechanical strength.

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A new technology for the joining by forming of magnesium alloys

Cited by 33 publications

References 6 publications

Development of a mechanical joining process for automotive body-in-white production

Development of a mechanical joining process for automotive body-in-white production

Experimental investigation on the mechanical square clinching process for joining Al5052 sheets

Experimental investigation of the novel dieless clinching process free of blank holder

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