Abstract
Three-dimensional modelling enables to determine the in-plane material flow in asymmetrical situation. Thus, the distortion of the sheets to be joined can be characterized more exactly. This study shows a method for building up a three-dimensional shear-clinching framework without damage criteria. In fact, the die-sided sheet in shear-clinching was designed as a pre-punched sheet and slugs. The material separation in the die-sided joining partner, which in two-dimensional simulation is often described by macro- and micromechanical fracture criteria, was realised in this study based on a defined contact condition. By means of a shear-cutting simulation, a correlation between the break angle and the separation stress was determined, which was used as a separation criterion in the shear-clinching simulation. The separation line was confirmed using post-particles. To validate this model, the results of the simulation using a quadratic single-point specimen were compared to the experiments with respect to the distortion of the joining partner. In general, the built three-dimensional framework provides for further tool developments with regard to the reduction of distortion in shear-clinching.
Highlights
Owing to the lightweight construction of car bodies, increased usage of lightweight materials, e.g., aluminium and magnesium, have been using in car body construction in addition to the classic steel materials
In order to determine the appropriate separation stress σ, the hole geometry after punching was considered in addition to the comparison of
A three-dimensional shear-clinching substitute framework is shown in this study, in which the axially symmetrical and asymmetrical distortions can be estimated with low computational effort
Summary
Owing to the lightweight construction of car bodies, increased usage of lightweight materials, e.g., aluminium and magnesium, have been using in car body construction in addition to the classic steel materials. Since the three-dimensional adaptive remeshing works in case of extreme deformation and subsequent material failure unstably in current commercial solvers, a full or partial three-dimensional model of a joining process, taking into consideration the fact that the material damage is still a challenge [13]. To overcome this difficulty in the simulation, some meshless approximations based on bond-based failure are common. The substitute modelling of shear-clinching with a material separation criterion, which is based on a defined separation stress of segments, is presented in this study
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