Hole Roller Clinching of Multi-Material-Lightweight Joints

机械和汽车工程显示出一个趋势，即单个部件的数量越来越多，部件的复杂性也越来越高。这些由不同材料制成的部件必须连接在一起。因此，连接技术的发展和适应是一个至关重要的方面。本研究项目中提出的连接方法--孔辊紧固，是第一个资助期研究的轧辊紧固工艺的延伸。在研究过程中，成功地开发了成形良好的金属材料滚压成形的优化工艺参数。现在，以轻量化结构为重点的混合构件的滚压紧固被研究。在这些多材料化合物中，很难形成一个加入的伙伴或只能在有限的范围内形成。因此，在拟议的研究项目中，将研究有纤维增强和无纤维增强的塑料以及高强度钢与具有良好成形性的材料相结合的滚压工艺参数。孔式滚压提供了扩展适合滚压的材料的能力。此外，压紧和冲压两种制造工艺的组合扩展了工艺参数集。该研究项目的主要目的包括：1.对实际使用的孔辊紧固工艺进行鉴定；2.用有限元模拟确定孔辊紧固工艺的参数范围；3.在金属成形与铸造研究所的试验台上对新的连接方法试验项目中开发和购置的工具进行重新设计和调整；4.分析工艺参数对结合点性能和接头力学性能的影响，并推导出优化接头强度的准则

Mechanical and automotive engineering reveals a trend towards an increasing number of individual parts as well as an increasing component complexity. These components, which are made of different materials, have to be joined. Therefore, the development and adaptation of joining technologies is a crucial aspect.The joining method proposed in this research project, hole roller clinching, is an extension of the roller clinching process examined in the first funding period. During the research project optimized process parameters for roller clinching of well formable metallic materials were successfully developed. Now, roller clinching of hybrid components with a focus on lightweight construction is investigated. In these multi-material compounds, one joining partner is difficult to form or the formation can only be achieved to a limited extend. Thus, the process parameters for roller clinching of plastics with and without fiber reinforcement as well as high strength steels combined with materials that offer good formability will be studied in the proposed research project.Hole roller clinching provides the ability to expand the materials suitable for roller clinching. In addition, the combination of two manufacturing processes, clinching and punching, extends the set of process parameters. Main focus of the investigations will be the joining process itself.The main objectives of the research project include:1.Qualification of the hole roller clinching process for use in practice2.Identification of parameter limits of the hole roller clinching process using finite element simulations3.Redesign and adaptation of the tool developed and procured in the project for the examination of the new joining method on the experimental test rig at the Institute of Metal Forming and Casting4.Analysis of process parameters with respect to their influence on the clinch point properties as well as the mechanical properties of the joint and deduction of guidelines for optimizing the joint strength