Simulation of the Clinching Process Using FEA Method with Steel and Aluminum Alloy Sheets for Automotive Sunroof Frame
|School||South China University of Technology|
|Keywords||Steel-aluminum Clinching G-T-N model Finite Element Analysis Simulation Mold Parameters Selecting Method|
With the development of automobile lightweight technologies, aluminum alloys are used more and more in car body design. However, conventional joining technologies, such as welding, face many restrictions when joining different materials such as steel and aluminum alloys.There are many factors which influence the quality of the clinched joint, such as the geometrical shape of the clinched joint, the design parameters of the tools, the sheet material properties and its thickness, the pressure applied during the process. The Finite Element Analysis (FEA) method is an effective alternative means of simulation. In this paper, the steel-aluminum pressure connection process simulation model is established, then verified by experiments, and from a theory of the steel-aluminum pressure connection formation system.Based on the material tension test, the Hollomon extrapolation flow stress model expression of steel Q235 material and aluminum alloy 5052 are determined. Through the simulation of tensile test, the influences of G-T-N model parameters are studied in this paper, then parameters are determined by simulation.The dynamic process of steel-aluminum clinching FEA model is established, the key technologies in the simulation process the application and the finite element results for the impact are discussed, such as meshing, materials division, contact algorithm, rate of amplification and ALE technology.With the numerical simulation, the initial parameters range are selected by the theory of mold parameters volume matching method, and then further by the finite element simulation methods to define the steel-aluminum clinching mold parameters. Finally, the correct selected parameters are verified by shear tests and peel tests. The FEA simulation results showed a theoretical reference value for the selection and design of mold parameters, especially for steel-aluminum clinching process. This paper will provide a good guide for the simulation of steel-aluminum clinching.