Abstract
Punctiform mechanical joining technologies, such as riveting, clinching, or screwing, which are widely used in sheet metal processing, are frequently applied because they have been established for many years. Depending on the process, they offer a variety of advantages such as one-sided accessibility, re-detachability, and no need for pre-punching operations or auxiliary joining elements. In addition, the processes often guarantee a high process reliability and extensive process monitoring. However, with thermoplastic composites, they lead to considerable stress concentrations at the joint due to the fibers. Undesirable fiber and inter-fiber breaks then result. With the development of the novel joining technology of joint stamp riveting, an improvement is achieved in this situation that has been described for hybrid joints on components made of thermoplastic composites and metal sheets. The joining principle is based on the formation of a form lock between the joining partners. The thermoplastic composite is thermomechanically formed by means of a joint stamp without using an auxiliary joining element. Within the scope of a research project, the joining process was characterized with regard to the structure of the joining spot, the geometry of the forming tools, and also the mechanical properties for purposes of analyzing and designing the joining process.
Highlights
The implementation of new construction methods and materials in vehicle and aircraft manufacturing is linked to the supply of reliable and more cost-effective joining technologies
The thermoforming approach according to [10] is used to ensure that a connection is achieved between the thermoplastic composite and the metal sheet
High characteristic values are determined during the mechanical tests
Summary
The implementation of new construction methods and materials in vehicle and aircraft manufacturing is linked to the supply of reliable and more cost-effective joining technologies. In the current fifth generation of the Audi A8 model [2], a mix of four materials is used in the body. This mix requires joining techniques that are appropriate to the materials and adapted to the respective requirements of the materials and the manufacturing and product-related conditions. A total of 13 different joining techniques are used to construct the body of the A8. Some of these joining technologies must be adapted to fiber-reinforced plastic material which is one of the materials employed
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