Mechanical joining of dissimilar materials by shear clinching processes without pre-punching (shear clinching)

通过剪切铆接工艺机械连接异种材料，无需预冲孔（剪切铆接）

• 批准号: 227633773
• 负责人: Professorin Dr.-Ing. Marion Merklein
• 金额: --
• 依托单位: Laboratorium für Werkstoff- und Fügetechnik (LWF)
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2012
• 资助国家: 德国
• 起止时间: 2011-12-31 至 2019-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/227633773?language=en
• 关键词: Mechanical; joining; dissimilar; materials; shear

Political and environmental requirements demand the use of adapted materials in modern lightweight design structures. Joining these dissimilar materials challenges the development and advancement of existing technologies. Great potential offers the innovative shear-clinching technology which is investigated in this project. The single-stage process offers the opportunity to join material combinations with significantly different material properties without additional joining elements or pre-holing and retrieval of this pre-hole. The combined inner- and outer punch initialize a cutting operation in the die-sided brittle material as well as a drawing process in the punch-sided ductile joining partner for creating a form- and force-fitting joint. This reduces the required process time and avoids possible positioning errors that occur during multi-stage processes. The third funding phase focuses on investigating and improving the robustness of the shear-clinching process and the predictability of the properties of a shear-clinched joint. Therefore, three key research areas are set.To evaluate the tool-related design, the active elements are analyzed in terms of tool wear and the resistance of the tool materials. In addition to the identification of the process limits, the influence of process and batch-related deviations on the quality of the joint formation and the tool wear are examined. Based on these results the tool elements are adjusted for high local stresses and wear tests are carried out. The second focus is the evaluation of the process design. For this purpose, the previously analyzed single-element samples are replaced by multi-element samples to examine the influence of neighboring points on joint formation. An essential approach is identifying the influence of the radial material flow on the characteristic joint properties and set limits of a robust joining process. The influences on the joint formation of joint distance, sheet thickness and additional process based deviations are analyzed. Multi-element samples of the described material combinations are tested concerning joint strength and corrosive behavior.The final research topic is the review of the shear-clinching process regarding process safety and tested material combinations. Therefore, the findings from the first two phases of the project are combined with the tool- and process-sided results and evaluated in terms of process reliability. In particular, the failure modes of the joints are taken into account for enabling a prediction of the joint properties. The transferability of these findings will be evaluated by arranging different punch-sided aluminium alloys. The project is finalized with the summary of the results and a holistic review of the shear-clinching process.

政治和环境需求要求在现代轻型设计结构中使用改编的材料。加入这些不同的材料挑战了现有技术的发展和进步。巨大的潜力提供了该项目中研究的创新剪切技术。单阶段的过程提供了与具有明显不同材料属性的材料组合的机会，而无需其他连接元素，或者预先填充和检索此预孔。结合的内和外拳在模板脆性材料中初始化了切割操作，以及在打孔的延性连接伙伴中的绘图过程，用于创建形式和力拟合的接头。这减少了所需的过程时间，并避免了多阶段过程中可能发生的定位错误。第三个融资阶段着重于研究和改善剪切临床过程的鲁棒性以及剪切夹关节的性质的可预测性。因此，设置了三个关键的研究领域。为了评估与刀具相关的设计，通过工具磨损和工具材料的阻力来分析活动元素。除了确定过程限制外，还检查了过程和批处理相关偏差对关节形成质量和工具磨损的影响。基于这些结果，对较高的局部应力进行了调整，并进行了磨损测试。第二个重点是对过程设计的评估。为此，先前分析的单元素样品被多元素样品取代，以检查相邻点对关节形成的影响。一种必不可少的方法是确定径向材料流对特性关节特性的影响，并确定强大的连接过程的设定限制。分析了关节距离，薄板厚度和其他基于过程偏差的关节形成的影响。对所述材料组合的多元素样品进行了有关关节强度和腐蚀性行为的测试。最终的研究主题是对剪切临床过程的综述，涉及过程安全性和测试材料组合。因此，项目的前两个阶段的发现与工具和过程侧面的结果相结合，并根据过程可靠性进行评估。特别是，关节的故障模式考虑了对关节特性的预测。这些发现的可转移性将通过排列不同的打孔铝合金来评估。该项目通过结果摘要以及对剪切临床过程的整体审查进行了最终确定。