Abstract
The hole-clinching process is one of the mechanical methods for joining dissimilar materials, such as aluminum alloy with advanced high-strength steel, hot-pressed steel, and carbon fiber reinforced plastics, employing forming technology-based methods. In joint design, the analysis of the failure-mode dependent joint strength is a crucial step in achieving structural performance for practical applications. In this study, the influence of the geometrical interlocking parameters on the failure-mode dependent joint strength was investigated in order to design the geometrical interlocking shape of the hole-clinched joint to achieve a target joint strength. Moreover, the failure process of the hole-clinched joint under pullout loading condition was studied to determine the geometrical interlocking parameters that affect joint strength. Based on the results of the finite element analysis, an analytical approach for the failure-mode dependent joint strength was proposed to predict the strength of the hole-clinched joint. In addition, the proposed analytical approach was applied to the hole-clinching process with dissimilar materials. Its effectiveness was then verified using the cross-tension test. Accordingly, it was found that it was possible to predict the failure modes and joint strength with a maximum error of 7.8%.
Highlights
The multi-material design concept is widely used in practical applications
The joint strengths and failure modes for all the experimental cases were evaluated to verify the effectiveness of the proposed analytical approach
In Cases 1 and 3, the undercut of the hole-clinched joint was fractured by shear stress, resulting in button separation. These results demonstrate that the joint strength for button separation indicates that the undercut fracture load was caused by shear stress
Summary
The multi-material design concept is widely used in practical applications. Structures designed with multi-materials utilize light-weight components, such as advanced high-strength steel, aluminum alloy, and carbon fiber reinforced plastic (CFRP), all of which are extensively used in automotive bodies [1,2,3]. The success of such multi-material designed structures greatly depends on the methods employed to join the body components made of dissimilar materials.
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