Description
Legal necessities for a reduction of CO2 emissions as well as increasing customer demands for comfort require an ongoing development of drive and car body concepts. One of the most important approaches regarding the body in white construction is the consequent implementation of lightweight materials. The combination of high-strength steel materials and nonferrous metals allows a weight reduction without decreasing crash-performance of the car. The high yield strength and low formability as well as the increase in the number of components and materials are major challenges for adapted joining technologies. The shear-clinching process offers great potential in this field of application. The combination of a cutting and a forming operation in a single stage process allows the joining of aluminum and ultra-high-strength steel sheets without a pre-holing operation or any auxiliary part.
In this context, this scientific work elaborated a comprehensive process understanding of the subprocesses and the combined shear-clinching technology. For this purpose, an adapted tool system as well as a damage-based numerical model of the cutting process were developed, based on previous investigations on the qualification of the shear-clinching process. Subsequently, numerical and experimental analyses of the subprocesses as well as experimental parameter studies were carried out. The results were used to identify effects on the shear-clinching joint as well as to develop guidelines for the practical application of the shear-clinching process.
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