加工时间对翻滚运动式自冲铆接工艺的影响

S. Wituschek, Leonie Elbel, Michael Lechner
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摘要

生态责任、更严格的政治法规和经济目标的重要性与日俱增,推动了轻质建筑等研究领域的创新。最重要的流行方法之一是使用多材料系统。由于所使用的各种材料具有不同的几何和机械特性,因此可以实现资源的高效应用和利用。由于传统的连接工艺已达到极限,实现这些多材料系统的连接工艺面临着巨大的挑战。在机械连接工艺领域,不断有新的方法出现,例如在自冲铆接工艺中将冲头与翻滚运动学叠加,以增加可适应的工艺参数数量并加强工艺控制。通过各种初步测试,我们对该工艺有了很好的了解,可以通过配置翻滚策略直接控制几何连接参数。一个主要的挑战,尤其是在未来的工业应用方面,是由于滚揉运动学而相对较高的工艺时间。在研究中,我们的目标是通过调整接合和翻滚策略来减少约 90% 的加工时间。因此,在一系列渐进实验中对横移速度和翻滚速度的相关性进行了研究。为了体现实际应用,实验使用了双相钢和沉淀硬化铝合金。为确定工艺参数对连接过程的影响,采用了恒定的铆钉-模具组合。此外,还对力-位移曲线进行了研究。此外,几何连接参数的确定依赖于宏观图,以评估连接时间对几何连接形成的影响。测试结果表明,大幅提高接合速度并由此缩短加工时间是可行的。虽然接合性能会受到影响,但可靠的接合是可能的。特别是,铆钉的轴厚度会受到接合操作中不同比例的翻滚过程的影响,并随着接合速度的提高而增加。
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Influence of the process time on a self-piercing riveting process with tumbling kinematic
The increasing significance of ecological responsibility, stricter political regulations and economic objectives are driving innovation in research fields such as lightweight construction. One of the most important popular methods is the use of multi-material systems. Due to the different geometric and mechanical properties of the various materials used, resource efficient applications and utilizations are possible. Great challenges arise for the joining processes to realize these multi-material systems, since conventional joining processes reach their limits. In the field of mechanical joining processes, there are continuously new approaches, such as superimposing the punch in a self-piercing riveting process with a tumbling kinematic, to increase the number of adaptable process parameters and enhance the process control. Through various preliminary tests, a good understanding of the process has been developed, which allows to directly control the geometric joint parameters by configuring the tumbling strategy. A major challenge, particularly with regard to future industrial applications, is the process time, which is comparatively high due to the tumbling kinematics. In the investigations, a reduction of approximately 90% of the process time is targeted by adapting the joining and tumbling strategy. Therefore, the correlation of the traverse velocity and the tumbling velocity are examined in a gradual series of experiments. To represent realistic applications, the experiments are carried out with a dual-phase steel and a precipitation-hardening aluminum alloy. For identifying the influence of the process parameters on the joining process, a constant rivet–die combination is applied. Further, the examination of force–displacement curves is conducted. Moreover, the determination of geometric joint parameters is reliant upon macrographs to assess the influence of the joining time on the geometric joint formation. The test results show that a significant increase in joining speed with a resulting reduction in process time is feasible. Although the joining properties are affected, reliable joining is possible. In particular, the shaft thickness of the rivet is influenced by the varying proportion of the tumbling process in the joining operation and increases with higher joining speeds.
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