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Parametric Study of Hybrid Metal-Composites Clinching Joints

authors:Dean, A.; Rolfes, R.; Behrens, B.-A., Hübner, S.; Chugreev, A.; Grbic, N.
categories:Journals (reviewed)
publication:Key Engineering Materials, ISSN: 1662-9795, Vol. 767, pp 413-420
isbn:1662-9795, Vol. 767, pp 413-420


In different innovative markets, such as electro mobility and flexible electronics, among others, the mechanical joining processes based on sheet metal forming technologies are gaining a significant relevance due to their low cost and ease of automation as compared to traditional joining techniques of riveting, bolting, fastening, welding, etc. In lightweight hybrid constructions, where a high production rate is required, clinching technology demonstrates a sustainable method to join hybrid metal-composite parts. However, the basic mechanisms of this hybrid joining process are not well studied at present and an accepted design theory in this area has not yet been established. The current contribution presents a parametric study of the hybrid clinching joining process. The Taguchi’s design of experiments method is used to investigate the effects of tools’ geometry on hybrid clinching joints’ quality characteristics, i.e. neck thickness, undercut and final bottom thickness. For this purpose, a 2D axisymmetric modelling approach was adopted for its simplicity. The study results are analyzed using the mean response and signal-to-noise ratio approaches. Accordingly, the relevant geometrical parameters of the tools with the highest influence on the accurate shaping of hybrid clinching joints are determined numerically.