Abstract
Clinching joints with an additional deformable rivet are modifications of the clinching joints. The clinch riveting (CR) joint is formed indirectly by a deformable rivet. The research included an analysis of CR joints’ forming process for aluminum alloy sheets made of AW 6082 in T6 state condition and AW 5754 in three different state conditions: H11, H22 and H24. As a result of forming the joint for various sheet arrangements, the highest value of blocking the upper sheet in the lower sheet (tu) was obtained for the arrangements with two 5754-H24 aluminum alloy sheets. For such a large interlock parameter tu, the greatest thinning of lower sheet (tn) was obtained, which influenced the maximum tensile shear force and the joint failure mechanism. Based on the load-displacement diagrams obtained from the static shear test of lap joints, the total energy of failure and energy to achieve the maximum load capacity were calculated. The highest energy absorption to achieve the maximum load capacity, in the case of the same sheet materials, was obtained for the 5754-H11 aluminum alloy sheets. On the other hand, among the tested combinations, the highest value of energy absorption (for the joint maximum load capacity) was obtained for the sheet arrangement: top sheet AW 6082-T6 and the bottom AW 5754-H24. The highest value of the total energy up to fracture was obtained when the material of the top sheet was AW 6082-T6, and the bottom AW 5754-H22. For each sheet arrangement, a similar analysis of the joint strength parameters, interlock parameters and forming force were made.
Highlights
In the automotive industry, aluminum sheet metal is commonly used to create a lightweight car body assembly
Other joining methods that can be used in the assembly process of aluminum elements are adhesive bonding, fastening, riveting, clinching, clinch riveting, self-piercing riveting or tabs bending [1,2]
Joints produced by adhesive bonding overcome the welding difficulties, even in joining sheets made from dissimilar materials, but their use is constrained by temperature, ageing due to weathering, long curing times and precision of surface preparation
Summary
Aluminum sheet metal is commonly used to create a lightweight car body assembly. Witkowski [6] presented the strength of clinching joints made by rigid tool for two sheet material: steel DX51D + Z/275 and the aluminum alloy EN AW-5754 in O/H111 state. Sabra Atia et al [13] presented a finite element modeling analysis of the influence of material and tool stiffness conditions on die-less clinch joining method characteristics. Ma et al [29] investigated the tensile shear strength and fracture mechanism of the friction self-piercing riveting technology (F-SPR: combination of self-piercing riveting and friction stir spot welding processes) for 7075-T6 aluminum alloy sheets. Ying et al [32] proposed joining aluminum with high strength and low ductility (such as AA7075-T6) by the SPR joining technology with pre-heating of the sheets, increasing the value of temperature influence on the interlock geometry and joints’ strength. The measurement results on the cross-section of the joint with the full deformable rivet were presented
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