Phenomena of forming and failure in joining hybrid structures – Experimental and numerical studies of clinching thermoplastic composites and metal

Vorderbrüggen, Julian; Gröger, B.; Kupfer, Robert; Hoog, Arne; Gude, Μaik; Meschut, Gerson

doi:10.1063/1.5112580

Cited by 13 publications

(15 citation statements)

References 7 publications

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“…It can clearly be seen that the undercut could not be predicted because the compaction in the neck area is too high. This stands in good agreement with 2D results of [1]. But the simulation shows a very sensible behaviour to the stacking position of the fabric.…”

Section: Model Set-up Model Set-upsupporting

confidence: 89%

“…The joining process under ambient temperature in [5] leads to a significant amount of fibre failure and delamination. Similar results were found in [1]. However, the development of a novel tool concept, employing a split die with a rigid sleeve and spring loaded anvil (Fig.…”

Section: Intr Introduction Oductionsupporting

confidence: 78%

“…In order to predict the material structure, fabric and the matrix material domains are modelled separately. The fabric is created with geometry data based on micrographs and modelled using a Lagrangian mesh with 2 elements over the thickness [1]. The matrix is simplified as a cuboid.…”

Section: Model Set-up Model Set-upmentioning

confidence: 99%

“…This requires novel joining methods and processes for a cost effective industrial application. The thermally supported clinching process (TSC) is such a novel single stage joining process without auxiliary parts or preliminary steps (e.g drilling) [1]. In order to apply this joining process in an adaptive manner for a variety of joining scenarios, a robust numerical strategy is necessary.…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

“…In this study, a description on meso scale of the TSC with the related geometric dimensions of the joining zone using a 2x2 twill fabric of glass fibre (GF) with a polyamid 6 (PA6) matrix and a DC05-metal sheet are considered. In [1] the optimal punch diameter was determined to be 5.8 mm and the width of a single roving 4.0 mm. In the present paper, modelling approaches using Lagrangian formulation (Arbitrary-Lagrangian-Eulerian (ALE) remeshing, SmoothParticleHydrodynamics (SPH)) and Eulerian formulation (CoupledEulerian-Lagrangian (CEL)) is be used to simulate the TSC joining process on mesoscale.…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

See 4 more Smart Citations

Modelling of thermally supported clinching of fibre-reinforced thermoplastics: Approaches on mesoscale considering large deformations and fibre failure

Gröger¹,

Hornig²,

Hoog³

et al. 2021

Esaform 2021

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Thermally supported clinching (Hotclinch) is a novel promising process to join dissimilar materials. Here, metal and fibre-reinforced thermoplastics (FRTP) are used within this single step joining process and without the usage of auxiliary parts like screws or rivets. For this purpose, heat is applied to improve the formability of the reinforced thermoplastic. This enables joining of the materials using conventional clinching-tools. Focus of this work is the modelling on mesoscopic scale for the numerical simulation of this process. The FTRP-model takes the material behaviour both of matrix and the fabric reinforced organo-sheet under process temperatures into account. For describing the experimentally observed phenomena such as large deformations, fibre failure and the interactions between matrix and fibres as well as between fibres themselves, the usage of conventional, purely Lagrangian based FEM methods is limited. Therefore, the combination of contact-models with advanced modelling approaches like Arbitrary-Lagrangian-Eulerian (ALE), Coupled-Eulerian-Lagrangian (CEL) and Smooth-ParticleHydrodynamics (SPH) for the numerical simulation of the clinching process are employed. The different approaches are compared with regard to simulation feasibility, robustness and results accuracy. It is shown, that the CEL approach represents the most promising approach to describe the clinching process.

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Section: Model Set-up Model Set-upsupporting

confidence: 89%

Section: Intr Introduction Oductionsupporting

confidence: 78%

Section: Model Set-up Model Set-upmentioning

confidence: 99%

Section: Intr Introduction Oductionmentioning

confidence: 99%

Section: Intr Introduction Oductionmentioning

confidence: 99%

See 3 more Smart Citations

Modelling of thermally supported clinching of fibre-reinforced thermoplastics: Approaches on mesoscale considering large deformations and fibre failure

Gröger¹,

Hornig²,

Hoog³

et al. 2021

Esaform 2021

Self Cite

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In-situ Computed Tomography and Transient Dynamic Analysis of a Single-Lap Shear Test with a Composite-Metal Clinch Point

Köhler

Stephan

Kupfer

et al. 2023

Lecture Notes in Production Engineering

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Computed tomography investigation of the material structure in clinch joints in aluminium fibre-reinforced thermoplastic sheets

Gröger

Köhler

Vorderbrüggen

et al. 2021

Prod. Eng. Res. Devel.

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Recent developments in automotive and aircraft industry towards a multi-material design pose challenges for modern joining technologies due to different mechanical properties and material compositions of various materials such as composites and metals. Therefore, mechanical joining technologies like clinching are in the focus of current research activities. For multi-material joints of metals and thermoplastic composites thermally assisted clinching processes with advanced tool concepts are well developed. The material-specific properties of fibre-reinforced thermoplastics have a significant influence on the joining process and the resulting material structure in the joining zone. For this reason, it is important to investigate these influences in detail and to understand the phenomena occurring during the joining process. Additionally, this provides the basis for a validation of a numerical simulation of such joining processes. In this paper, the material structure in a joint resulting from a thermally assisted clinching process is investigated. The joining partners are an aluminium sheet and a thermoplastic composite (organo sheet). Using computed tomography enables a three-dimensional investigation that allows a detailed analysis of the phenomena in different joining stages and in the material structure of the finished joint. Consequently, this study provides a more detailed understanding of the material behavior of thermoplastic composites during thermally assisted clinching.

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Phenomena of forming and failure in joining hybrid structures – Experimental and numerical studies of clinching thermoplastic composites and metal

Cited by 13 publications

References 7 publications

Modelling of thermally supported clinching of fibre-reinforced thermoplastics: Approaches on mesoscale considering large deformations and fibre failure

Modelling of thermally supported clinching of fibre-reinforced thermoplastics: Approaches on mesoscale considering large deformations and fibre failure

In-situ Computed Tomography and Transient Dynamic Analysis of a Single-Lap Shear Test with a Composite-Metal Clinch Point

Computed tomography investigation of the material structure in clinch joints in aluminium fibre-reinforced thermoplastic sheets

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