Abstract
The paper presents results of a FEA-based tool design optimisation for a clinching process with an open multiple-part die. The studied materials are the bake-hardening steel CR240BH (1.5 mm) on the punch side and the die-cast aluminium alloy AlSi10MnMg (2.95 mm) on the die side. The objective of the optimisation was to minimise probability of cracks that appear at the outer circumference of the bottom of the clinch joint in AlSi10MnMg. In the framework of the optimisation, it was possible to minimise crack probability by varying geometrical parameters of the tools though at the cost of slightly worse but still tolerable geometrical parameters of the clinch joint.
Highlights
The joining method clinching has been used in the automotive manufacturing since a decade because of its efficiency, cleanliness and low noise
The objective of the present study was the FEA-based optimisation of the tool design of a clinching process with an open multiple-part die aimed at damage minimisation in CR240BHAlSi10MnMg joints
The criterion parameters were referred from the literature for a similar aluminium alloy while the critical value of the damage variable was obtained based on the comparison between the experimental and numerical results of the studied clinching process
Summary
The joining method clinching has been used in the automotive manufacturing since a decade because of its efficiency, cleanliness and low noise. According to the standard DIN 8593, the mechanical joining processes are listed under the group “joining by forming” [1]. These are divided in processes with and without auxiliary joining elements. Clinching involves the joining methods by local. Two materials are formed to be joined into a die by a punch. Clinching has a great potential for weight minimisation of the joining components and economic benefits. It is thicknesses, e.g. for steel and aluminium [3, 4]
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