Abstract
The manufacturing research has been focusing on the improvement of product performance and lightweight design. The synergic effects between material properties and manufacturing solutions have been considered, extensively. Specifically, joining techniques have been developing with the aim to propose new suitable solutions considering dissimilarities in the properties of the materials that have to be combined. Setting of new manufacturing routes is, therefore, a demanding task. In this direction, there are several methods available in the scientific literature that are focused on sensitivity analysis or optimization/minimization techniques to reduce the necessary attempts or to find a solution/correlation among big data. In this work, the goal of obtaining high joint efficiency between Aluminum and Polycarbonate sheets by the Friction Spot Joining process is considered as a case study. This process must face two main issues, i.e., the mechanical, physical and chemical compatibilities between the parts and the integrity protection of the polymeric sheet near the joining area. The process parameters influences were analysed using numerical simulations performed by a commercial FE code. The number of executed analyses was reduced with a planned DoE. From these results, the Code2Vect algorithm was employed with the aim to visualize, efficiently, high-dimensional data and to evaluate the influences of some identified parameters on the process answer. Finally, a transfer function involving the input and output quantities of interest was derived in a compact representation by a Newton Raphson minimization technique.
Highlights
As continuously demanded by aerospace and automotive industries, academic and industrial research have been focusing on the development of lightweight components for pursuing both CO2 reduction and performant solutions through the combination of different lightweight materials such as Aluminum, Magnesium alloys and thermoplastic materials
Which highlights the classification of the heterogeneous data and aims at emphasizing the classification and nonlinear regression capabilities of this technique and, in conclusion, the compact equations obtained from the Newton-Raphson minimization technique
To assess the joint efficiency, the maximum temperature of the PC sheet in two specific zone close to the friction-heated aluminum side, and the interlocking area between the sheets were evaluated from all simulation results
Summary
As continuously demanded by aerospace and automotive industries, academic and industrial research have been focusing on the development of lightweight components for pursuing both CO2 reduction and performant solutions through the combination of different lightweight materials such as Aluminum, Magnesium alloys and thermoplastic materials In this context, the main goal is the development of peculiar techniques suitable to joint these materials through the optimization of advanced and sustainable connections. PIMM, Arts et Métiers Institute of Technology, CNRS, CNAM, HESAM University, 151, boule-vard de l’Hôpital, 75013 Paris, France. When an Aluminum alloy is joined with a thermoplastic material, two main problems can arise, i.e., the mechanical, physical and chemical compatibilities between the parts and the preservation of the polymeric sheet nearby the joining area To face these issues, the effects of the process parameters on the joint quality need to be understood by means of numerical and experimental tests and data analysis
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