Hole Roller Clinching of Multi-Material-Lightweight Joints

机械和汽车工程显示出越来越多的单个零件以及越来越多的组件复杂性的趋势。这些由不同材料制成的部件必须连接在一起。因此，连接技术的开发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--孔辊压接，是第一个资助期内研究的辊压接工艺的延伸。在研究项目中，成功地开发了用于成形性良好的金属材料的辊压铆接的优化工艺参数。现在，混合构件的滚柱铆接以轻质结构为重点进行了研究。在这些多材料化合物中，一个连接伴侣难以形成或形成仅能在有限程度上实现。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辊压铆接的工艺参数。孔辊压铆接提供了扩展适合辊压铆接的材料的能力。此外，两种制造工艺（铆接和冲压）的组合扩展了工艺参数集。调查的主要重点将是加入过程本身。研究项目的主要目标包括：1.孔辊压接工艺在实践中使用的资格2.使用有限元模拟确定孔辊压接工艺的参数限制3.重新设计和调整项目中开发和采购的工具，以在金属成型和铸造研究所的实验试验台上检查新的连接方法4.分析工艺参数对压接点性能以及接头的机械性能的影响，并推导出优化接头强度

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