Hybrid joining: Numerical process development of flat-clinch-bonding

Gerstmann, Thoralf; Awiszus, Birgit

doi:10.1016/j.jmatprotec.2019.116421

Cited by 35 publications

(12 citation statements)

References 16 publications

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“…The following are the limited few studies found in the literature. Gerstmann et al [83] described the development of a special type of clinching, namely flat-clinch bonding that combines flat clinching and adhesive bonding, using numerical simulations. In their work special attention was paid to material characterization and implementation of data in the simulation model.…”

Section: Clinch Bondingmentioning

confidence: 99%

A Review of Structural Adhesive Joints in Hybrid Joining Processes

et al. 2021

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Hybrid joining (HJ) is the combination of two or more joining techniques to produce joints with enhanced properties in comparison to those obtained from their parent techniques. Their adoption is widespread (metal to metal joint, composite to composite and composite to metal) and is present in a vast range of applications including all industrial sectors, from automotive to aerospace, including naval, construction, mechanical and utilities. The objective of this literature review is to summarize the existing research on hybrid joining processes incorporating structural adhesives highlighting their field of application and to present the recent development in this field. To achieve this goal, the first part presents an introduction on the main class of adhesives, subdivided by their chemical nature (epoxy, polyurethane, acrylic and cyanoacrylate, anaerobic and high-temperature adhesives) The second part describes the most commonly used Hybrid Joining (HJ) techniques (mechanical fastening and adhesive bonding, welding processes and adhesive bonding) The third part of the review is about the application of adhesives in dependence of performance, advantage and disadvantage in the hybrid joining processes. Finally, conclusions and an outlook on critical challenges, future perspectives and research activities are summarized. It was concluded that the use of hybrid joining technology could be considered as a potential solution in various industries, in order to reduce the mass as well as the manufacturing cost.

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Section: Clinch Bondingmentioning

confidence: 99%

A Review of Structural Adhesive Joints in Hybrid Joining Processes

et al. 2021

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“…This equation is defined within the FE-tool simufact.forming, and by applying the method of least squares, the coefficients C 1 and C 2 for Equation (5) can be determined for each test temperature from Equation (3). In [12] the approach for determining the coefficients is explained. Table 1 shows the determined coefficients for the corresponding testing temperature.…”

Section: Numerical Analysis Of the Forming Behavior In Comparison To The Experimental Data For Hot Air Rivetingmentioning

confidence: 99%

“…The suitability of material characterization by means of cylindrical upsetting tests for plastics in the solid state for compressive stresses was demonstrated in [11]. Furthermore, the numerical simulation and verification of the behavior of molten adhesive by means of a rate-power-law model was carried out in [12]. The approaches used in this thesis are therefore suitable.…”

Section: Numerical Analysis Of the Forming Behavior In Comparison To The Experimental Data For Hot Air Rivetingmentioning

confidence: 99%

“…Furthermore, the combined friction model with µ = 0.1 and m = 0.5 was used to calculate the friction shear stress. A detailed description of the combined friction model is given in [12]. Figure 11 shows the basic simulation setup at the beginning (a) and at the end of the process (b).…”

Section: Numerical Analysis Of the Forming Behavior In Comparison To The Experimental Data For Hot Air Rivetingmentioning

confidence: 99%

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Development of a Numerical Model of the Hot Air Staking Process Based on Experimental Data

et al. 2020

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Intelligent light weight concepts are increasingly designed as multi-material systems in order to achieve optimized properties through a targeted combination of materials. For these applications, the market demands joining technologies that make it possible to join foreign materials reliably (e.g., incompatible thermoplastics, thermoplastic-metal and thermoplastic-thermoset). In view of these industrial challenges, thermoplastic staking is an established forming process. At present, computer-aided development and precise FE-simulation (finite element-simulation) of these processes are not state-of-the-art. Accordingly, the previous design is based on subjective empirical values and empirical tests of the component. Within the framework of the paper, these gaps are to be closed by the development of numerical models for the heating and forming behavior of thermal plastic rivets (hot air staking) and the associated experimental validation. This requires the experimental development of the cause-effect relationships between melt formation and the resulting forming behavior. Finally, the numerical simulation shows a high conformity to the experimental data and allows an evaluation of the minimum heating time as well as initial approaches to evaluating the resulting structures by the simulation.

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“…Peeling joint strength depended on the width of the interlock in the upper sheet. Gerstmann et al [ 15 ] studied the flat clinch-bonding process (flat-clinching and adhesive bonding) for 1050A aluminum alloy sheets. Results from experimental tests were implemented to the simulation model.…”

Section: Introductionmentioning

confidence: 99%

Research on the Influence of the AW 5754 Aluminum Alloy State Condition and Sheet Arrangements with AW 6082 Aluminum Alloy on the Forming Process and Strength of the ClinchRivet Joints

2021

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Clinching joints with an additional deformable rivet are modifications of the clinching joints. The clinch riveting (CR) joint is formed indirectly by a deformable rivet. The research included an analysis of CR joints’ forming process for aluminum alloy sheets made of AW 6082 in T6 state condition and AW 5754 in three different state conditions: H11, H22 and H24. As a result of forming the joint for various sheet arrangements, the highest value of blocking the upper sheet in the lower sheet (tu) was obtained for the arrangements with two 5754-H24 aluminum alloy sheets. For such a large interlock parameter tu, the greatest thinning of lower sheet (tn) was obtained, which influenced the maximum tensile shear force and the joint failure mechanism. Based on the load-displacement diagrams obtained from the static shear test of lap joints, the total energy of failure and energy to achieve the maximum load capacity were calculated. The highest energy absorption to achieve the maximum load capacity, in the case of the same sheet materials, was obtained for the 5754-H11 aluminum alloy sheets. On the other hand, among the tested combinations, the highest value of energy absorption (for the joint maximum load capacity) was obtained for the sheet arrangement: top sheet AW 6082-T6 and the bottom AW 5754-H24. The highest value of the total energy up to fracture was obtained when the material of the top sheet was AW 6082-T6, and the bottom AW 5754-H22. For each sheet arrangement, a similar analysis of the joint strength parameters, interlock parameters and forming force were made.

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Hybrid joining: Numerical process development of flat-clinch-bonding

Cited by 35 publications

References 16 publications

A Review of Structural Adhesive Joints in Hybrid Joining Processes

A Review of Structural Adhesive Joints in Hybrid Joining Processes

Development of a Numerical Model of the Hot Air Staking Process Based on Experimental Data

Research on the Influence of the AW 5754 Aluminum Alloy State Condition and Sheet Arrangements with AW 6082 Aluminum Alloy on the Forming Process and Strength of the ClinchRivet Joints

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