Abstract
The predictive quality of numerical simulations for mechanical joining processes depends on the implemented material model, especially regarding the plasticity of the joining parts. Therefore, experimental material characterization processes are conducted to determine the material properties of sheet metal and generate flow curves. In this regard, there are a number of procedures which are accompanied by varying experimental efforts. This paper presents various methods of determining flow curves for HCT590X as well as EN AW-6014, including varying specimen geometries and diverse hardening laws for extrapolation procedures. The flow curves thus generated are compared considering the variety of plastic strains occurring in mechanical joining processes. The material data generated are implemented in simulation models for the joining technologies, clinching and self-piercing riveting. The influence of the varied methods on the predictive accuracy of the simulation model is analysed. The evaluation of the differing flow curves is achieved by comparing the geometric formation of the joints and the required joining forces of the processes with experimentally investigated joints.
About the authors
MSc Max Böhnke, born in 1994, studied Mechanical Engineering at Paderborn University, Germany. After completing his Master’s thesis at the Benteler Group in 2019 (Paderborn, Germany), he became a Research Assistant in the Laboratory for Material and Joining Technology at Paderborn University in February 2020. His research focuses on the testing and characteristics of mechanical joining processes.
MSc Fabian Kappe, born in 1994, studied Mechanical Engineering at the South Westphalia University of Applied Sciences and Paderborn University, Germany. After completing his Master’s thesis at Paderborn University in 2019, he became a Research Assistant in the Laboratory for Material and Joining Technology at Paderborn University in October 2019. His research focuses on self-pierce riveting by multi-material design.
Dr.-Ing. Mathias Bobbert, born in 1985, studied Mechanical Engineering at Paderborn University, Germany. He became a Research Assistant in the Laboratory for Material and Joining Technology in Paderborn University in November 2011. His research focuses on the simulation of adhesively bonded joints and mechanical joining in versatile process chains.
Prof. Dr.-Ing. Gerson Meschut, born in 1967, has been the Head of the Laboratory of Material and Joining Technology (LWF) at Paderborn University since September 2011. After his Diploma thesis in Mechanical Engineering at the University of Paderborn, he worked as a PhD student at the LWF and completed his Doctor’s degree summa cum laude in 1998. In the following period, he was employed as Chief Engineer for several research projects in the fields of adhesive bonding and hybrid joining technologies. At the beginning of 2000, he joined the Research and Development department of Volkswagen AG in Wolfsburg and was responsible for the optimization of the existing and the development of the new joining systems for innovative lightweight car body concepts. Before he joined the faculty at Paderborn University, he was employed as Technical Managing Director in Wilhelm Böllhoff GmbH & Co. KG in Bielefeld from 2005 to 2011. His focus in Paderborn is the development of suitable joining technologies especially for hybrid and multi- material design. An additional competence is the development of experimental and numerical methods for the process simulation and stress analysis or the joined lightweight structure service life forecast.
Acknowledgement
Funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) – TRR 285 – Project-ID 418701707. In particular, the authors wish to express their most sincere gratitude to Mr. Christian R. Bielak for his valuable assistance in building up the simulation models and evaluating the results.
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