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y
1
t
C
!
1
p
2
4
3
5
0
f
P
eff
1
where
0
is the yield stress in constant strain rate,
t
is the
effective strain rate and C and P are the parameters of strain
rate; f (
eff
P
) is the hardening coefficient which is based on the
effective plastic strain. Mooney-Rivlin elastic rubber model
was used for the rubber spring.
Some criteria such as the von Mises yield criterion, the
piecewise-linear isotropic strain-hardening rule and the asso-
ciated flow rule were adopted in simulations. The friction
between different parts in the model has an effect on the
profile of the extensible die clinched joints. In the lack of
experimental data, tentative values of the Coulomb friction
coefficient between different parts in the extensible die
clinching process model were assumed as follows: f=0.25
punch-upper sheet, f =0.15 upper sheet-blank holder, f =
0.15 upper sheet-lower sheet and f =0.25 lower sheet-
die. These values were kept constant for the simulations
in this study.
To save simulation time, start the analysis at the moment
when the punch was very close to the top surface of the upper
sheet and apply a specified initial velocity to simulate the
extensible die clinching process. The extensible die clinching
process is modelled by applying a downward initial velocity
to every node within the punch. Figure 3e shows the radial
displacement of sliding sector in the extensible die clinching
process FE simulation.
3 Extensible die clinching process tests
A clinching equipment RIVCLINCH 1106 P50 system was
employed as clinching machine as shown in Fig. 3a. All
clinching joints were made with constant pre-clamp (4 kN)
and setting load (50 kN). As shown in Fig. 3c, the diameter of
the punch is 5 mm and all clinching joints were formed for the
Fig. 6 Force-displacement curves and tensile strengths normal probability density distributions of clinched joints and clinch-bonded hybrid joints
Int J Adv Manuf Technol
same depth sensor. The average value of the bottom thickness
is 1.4 mm. The cross-section comparison between simulations
and tests of extensible die clinching processes is shown in
Fig. 4. It is clear that the result obtained from tests agree fairly
well with the computational simulation. The results show the
capability of the FE model for simulating the extensible die
clinching process for different geometries and work
conditions.
4 Deformation and failure of clinched joints
Clinching has found applications in heavy-duty situation, such
as car bodies. Load-bearing capacity and energy absorption
(EA) are the two most important features in structural analysis
of clinched joints. During the clinching process, the upper
sheet undergoes a significant thinning near the punch corner
radius. The strength of an extensible die clinched joint de-
pends on the joint profile and particularly on the neck thick-
ness and the magnitude of the produced undercut.
In order to improve the mechanical properties of the
clinched joints, it is also important for clinching to benefit
from the advantages of other fastening techniques, for exam-
ple adhesive bonding [22]. Adhesives are used to increase the
rigidity and tightness of the structure [23, 24]. It is commonly
understood that the addition of adhesive in clinched joints is
beneficial but it is not clear if there are negative effects on
mechanical properties of clinched joints. Deformation and
failure of homogeneous clinched joints under tensile loading
were investigated for validating the load-bearing capacity and
EA of clinched joints and clinch-bonded hybrid joints.
The clinch-bonded hybrid joints were produced following
exactly the same procedure as the respective clinched joints.
The adhesive used in the present study was two components
acryloid cement. The mechanical properties of the adhesive
investigated were Youngs modulus 2 GPa and Poissons ratio
0.30 which had been proved as an excellent adhesive property
[25]. The adhesive was applied on degreased surfaces and the
two sheets were pressed together in order to squeeze sufficient
adhesive out to avoid undue quilting of the finished clinch-
bonded hybrid joints. The flow of the adhesive was removed.
The clinching processes were then produced before adhesive
curing. The thickness of the adhesive layer was controlled by
the clinching process. The average values of the bottom
thickness of the clinch-bonded hybrid joints is 1.5 mm thus
the thickness of the adhesive layer is estimated to be 0.1 mm.
Thereafter, the adhesive was cured at room temperature for at
least 24 h. After curing, the adhesive layer can give strong
adhesive forces between sheets. Figure 5 shows the clinched
joints and clinch-bonded hybrid joints.
A servo-hydraulic testing machine was used for the mono-
tonic tensile tests of the clinched joints and clinch-bonded
hybrid joints. For each test, six samples were mechanically
tested. The distance between two grips was about 100 mm.
The tests were performed with a constant displacement rate of
1 mm/min and terminated when the sheets were separated or
the force drops to 20 % of the peak force value. Continuous
records of the applied force-displacement curves were obtain-
ed during each test. Figure 5a, b show the monotonic tensile
process and failed joints separately. It is clear from Fig. 5a, b
that the failure modes of the clinched joints and clinch-bonded
hybrid joints were neck fracture mode, as shown in Fig. 5c.
Fig. 7 Energy absorption normal probability density distributions of clinched joints and clinch-bonded hybrid joints
Maximum Force
[kN]
EA
[J]
Fig. 8 Intercepts of strength and EA for clinched joints and clinch-
bonded hybrid joints
Int J Adv Manuf Technol
Such failure of the clinched joints and clinch-bonded hybrid
joints could be attributed to a too small clearance of the tools
diameters or a too deep die.
Under the tensile-shear load, the neck of the upper sheet
bear a main shear load by geometrical interlocking. When the
shear stress reaches the yield criterion of aluminium alloy
Al5754, a crack is initiated from the interfacial surface of the
upper sheet and grows into the upper sheet thickness. After
rowing into the upper sheet, crack kinks towards the button
centre and then propagates along the circumference of the
button neck of the upper sheet. Finally, the inner button is
sheared off at the neck. In Fig. 5a, sheets were separated for
five samples and not completely separated for one sample.
Figure 6 shows the force-displacement curves of the
clinched joints and clinch-bonded hybrid joints. In the case
of the clinched joints, after the peak, the force decreases
gradually. In the cases of the clinch-bonded hybrid joints,
however, after the peak, the force suddenly drops. It is clear
from Fig. 6 that the load-bearing capacity of clinch-bonded
hybrid joint is higher than that of the clinched joint. It is also
clear from Figs. 5 and 6 that the repeatability of the clinched
joints and clinch-bonded hybrid joints are big though the
repeatability of the adhesive joints was not very big [5].
To examine the rationality of the test data, the normal
hypothesis tests were performed using MATLAB 7.0. The
results indicated that the tensile strengths of all the clinched
joints and clinch-bonded hybrid joints follow normal distribu-
tions. The mean values () and standard deviations () have
the following numerical values: for the clinched joints
C
=
1,895.30 N,
C
=43.81; for the clinch-bonded hybrid joints
CB
=2,022.50 N,
CB
=49.41. All test data fitting the region
was estimated by the degree of confidence of 95 %. The
tensile strengths normal probability density distributions of
the clinched joints and clinch-bonded hybrid joints are also
shown in Fig. 6.
5 EA of clinched joints and clinch-bonded hybrid joints
The normal hypothesis tests were performed to examine the
rationality of the EAvalues of the clinched joints and clinch-
bonded hybrid joints. The results show that the EA values of
all the clinched joints and clinch-bonded hybrid joints follow
normal distributions. For the clinched joints
EAC
=1.28 J,
EAC
=0.04; for clinch-bonded hybrid joints
EACB
=1.37 J,
EACB
=0.16. All test data fitting the region was estimated by
the degree of confidence of 95 %. The EA values normal
probability density distributions of the clinched joints and
clinch-bonded hybrid joints are shown in Fig. 7.
Fig. 8 shows the intercept for load-bearing capacity and EA
of the clinched joints and clinch-bonded hybrid joints. It is
clear that both the maximumload and EAvalues of the clinch-
bonded hybrid joints are higher than that of the clinched joint.
This means that the addition of adhesive resulted in an in-
crease in both the load-bearing and the energy absorption
capacities of the clinched joints.
6 Summary
The extensible die clinching process has been computationally
investigated in this paper using the commercial FE software
LS-Dyna. Experimental tests on the extensible die clinched
joints made of aluminium alloy Al5754 have been carried out
to validate the numerical simulation of the extensible die
clinching process. The result obtained from tests agreed fairly
well with the computational simulation.
Deformation and failure of homogeneous clinched joints
under tensile loading were investigated for validating the load-
bearing capacity and EA of the clinched joints and clinch-
bonded hybrid joints.
As mentioned above, the clinched joints were produced
before adhesive curing. In the extensible die clinching pro-
cess, adhesive layer can be fully sandwiched between two
sheets. After curing, the adhesive layer can increase the
strength of the clinched joints due to the adhesion mechanism.
However, after the peak load, the failure of adhesive layer
occurs in a brittle manner. In this case, though the clinch still
keeps the sheets connected, the joint can only bear low load,
resulting in some more elongation.
Acknowledgments Financial support of the National Natural Science
Foundation of China (Grant No. 50965009) is gratefully acknowledged.
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