Joining sheets made from dissimilar materials by hole hemming

2022 ◽  
pp. 146442072110726
Author(s):  
Mohammad Mehdi Kasaei ◽  
Lucas FM da Silva
Keyword(s):  
Mechanical Properties ◽  
Research Work ◽  
Dissimilar Materials ◽  
Element Analysis ◽  
Lightweight Structures ◽  
Lap Shear ◽  
Gradual Failure ◽  
Peel Tests ◽  
Dp780 Steel ◽  
Joining Process

This research work presents a new joining process based on the hemming process for attaching sheets made from dissimilar materials with very different mechanical properties. The process is termed ‘hole hemming’ and consists in producing a mechanical interlock between pre-drilled holes which can be made anywhere on the sheets. The process is carried out in a two-stage operation including flanging the hole of an outer sheet and bending the flange over the hole of an inner sheet. First, the joining stages and the required tools are designed. Then, the joining of DP780 steel and AA6061-T6 aluminium alloy sheets, which are applied to manufacture lightweight structures in the automotive industries, is investigated using finite element analysis. Results show that the hole hemming process is able to successfully join these materials without fracture. The hole-hemmed joint withstood the maximum forces of 2.5 and 0.5 kN in single-lap shear and peel tests, respectively, and failed with hole bearing mode which is known as a gradual failure mode. The results demonstrate the applicability of the hole hemming process for joining dissimilar materials.

Design of the Lightweight Structure and its Mechanical Properties

2013 ◽  
Vol 461 ◽  
pp. 57-62
Author(s):  
Xiao Ting Jiang ◽  
Ce Guo ◽  
Xiu Yan Cao ◽  
Zhen Yu Lu
Keyword(s):  
Mechanical Properties ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Fiber Material ◽  
Element Analysis ◽  
Static Compression ◽  
Lightweight Structures ◽  
Carbon Fiber Material ◽  
The Finite Element Analysis ◽  
Lightweight Structure

Based on the microstructure of the cross-section of the beetle's elytra, a kind of bio-inspiredlightweight structure was designed and made by the carbon fiber material. The compressive andshear mechanical properties of the lightweight structures were studied with finite element method.In addition, quasi-static compression experiments of the structure samples were carried out. Theexperimental results and the finite element analysis results were compared and analyzed, whichproved the effectiveness of the finite element analysis.

scholarly journals Dynamic Behavior of Self-Piercing Riveted and Mechanical Clinched Joints of Dissimilar Materials: An Experimental Comparative Investigation

2019 ◽  
Vol 2019 ◽  
pp. 1-12 ◽  
Author(s):  
Yulong Ge ◽  
Yong Xia
Keyword(s):  
Mechanical Behavior ◽  
Failure Modes ◽  
Dissimilar Materials ◽  
Dynamic Effect ◽  
Comparative Investigation ◽  
Rate Dependent ◽  
Lap Shear ◽  
Baking Process ◽  
Before And After ◽  
Peel Tests

The present work compares the dynamic effect of a self-piercing riveted (SPR) joint with that of a mechanical clinched joint having the dissimilar materials combination. The substrates used in this investigation are aluminum alloy AA5182-O and deep drawing steel DX51D+Z. The static and dynamic behaviors and the failure modes of the SPR and clinching joints are characterized by lap-shear, cross-tension, and coach-peel tests. The influence of the strain-rate-dependent mechanical behavior of the substrates on the joints is examined; this can help improve prediction of the energy absorption of the joints under impact loading. Considering the realistic baking process in a painting shop, the deforming and hardening effects on the SPR and the clinched joints induced by baking are also studied. The specimens are heated to 180°C for 30 min in an oven and then cooled down in air. The SPR and the clinched joints before and after the baking process are compared in terms of the mechanical behavior.

Failure Mechanism of Laser Welds in Lap-Shear Specimens of a High Strength Low Alloy Steel

2012 ◽  
Vol 134 (6) ◽  
Author(s):  
Jaewon Lee ◽  
Kamran Asim ◽  
Jwo Pan
Keyword(s):  
Mechanical Properties ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Failure Mechanism ◽  
Shear Failure ◽  
High Strength ◽  
Element Analysis ◽  
Lap Shear ◽  
Laser Welds ◽  
The Finite Element Analysis

In this study, the failure mechanism of laser welds in lap-shear specimens of a high strength low alloy (HSLA) steel under quasi-static loading conditions is examined based on the experimental and computational results. Optical micrographs of the welds in the specimens before tests were examined to understand the microstructure near the weld. A micrographic analysis of the failed welds in lap-shear specimens indicates a ductile necking/shear failure mechanism near the heat affected zone. Micro-hardness tests were conducted to provide an assessment of the mechanical properties of the joint area which has varying microstructure due to the welding process. A finite element analysis was also carried out to identify the effects of the weld geometry and different mechanical properties of the weld and heat affected zones on the failure mechanism. The results of the finite element analysis show that the geometry of the weld protrusion and the higher effective stress–plastic strain curves of the heat affected and weld zones result in the necking/shear failure of the load carrying sheet. The deformed shape of the finite element model near the weld matches well with that near a failed weld. A finite element analysis based on the Gurson yield function with consideration of void nucleation and growth was also carried out. The results of the finite element analysis indicate that the location of the material elements with the maximum void volume fraction matches well with that of the initiation of ductile fracture as observed in the experiments.

Analysis and Correlation of Output Parameters against Input Parameters for Friction Stir Welding of Three Dissimilar Aluminum Alloy

2018 ◽  
Vol 1146 ◽  
pp. 38-43
Author(s):  
Ana Boşneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Cristian Ciucă
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Arc Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Joints ◽  
Aluminum Plates ◽  
Joining Process

Friction Stir Welding, abbreviated FSW is an innovative joining process. The FSW is a solid-state welding process with a lot of advantages comparing to the traditional arc welding, such as the following: it uses a non-consumable tool, it results of good mechanical properties, it can use dissimilar materials and it have a low environmental impact. First of all, the FSW process was developed to join similar aluminum plates, and now, the technology was developed and the FSW process is used to weld large types of materials, similar or dissimilar. In this paper it is presented an experimental study and the results of it, which includes the welding of three dissimilar aluminum alloy, with different chemical and mechanical properties. This three materials are: AA2024, AA6061 and AA7075. The welding joints and the welding process were analyzed considering: process temperature, micro-hardness, macrostructure and microstructure.

scholarly journals Validation of a Simulation Methodology for Thermoplastic and Thermosetting Composite Materials Considering the Effect of Forming Process on the Structural Performance

Polymers ◽  
2020 ◽  
Vol 12 (12) ◽  
pp. 2801
Author(s):  
Lorenzo Sisca ◽  
Patrizio Tiziano Locatelli Quacchia ◽  
Alessandro Messana ◽  
Andrea Giancarlo Airale ◽  
Alessandro Ferraris ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Composite Materials ◽  
Research Work ◽  
Thickness Variation ◽  
Forming Process ◽  
Element Analysis ◽  
Mapping Tool ◽  
The Press ◽  
Thermoforming Process ◽  
Thermosetting Composite

This research work investigated the influence of the press molding manufacturing process on the mechanical properties, both for thermoplastic and thermosetting fiber reinforced composite materials. The particular geometry of the case study, called Double Dome, was considered in order to verify the behavior of the Thermoplastic and Thermosetting prepreg in terms of shell thickness variation and fibers shear angle evolution during the thermoforming process. The thermoforming simulation was performed using LS-DYNA® Finite Element Analysis (FEA) code, and the results were transferred by Envyo®, a dedicated mapping tool, into a LS-DYNA® virtual model for the structural simulation. A series of Double Dome specimens was produced with industrial equipment, and a bending experimental test was been carried on. Finally, a numerical-experimental correlation was performed, highlighting a significant forecast of the mechanical properties for the considered component.

Failure Stress Analysis of Adhesive T-Joint under Moisture Condition

2015 ◽  
Vol 786 ◽  
pp. 94-98
Author(s):  
S. Nurhashima ◽  
Mohd Afendi ◽  
Basirom Izzawati ◽  
A. Nor ◽  
Abdul Rahman Abdullah ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Room Temperature ◽  
Hot Water ◽  
Failure Stress ◽  
Element Analysis ◽  
Moisture Condition ◽  
Lightweight Structures ◽  
Test Compression ◽  
The Finite Element Analysis ◽  
Good Agreement

The use of adhesive structural in joining application offers the great demand due to its many advantages such as lightweight structures and flexible design. However, moisture provides significant problem and adverse effect on degrading the adhesive. The strength of the adhesive reduces because mechanical properties are known to reduce also with moisture environment. Therefore, this paper discusses about the adhesive T-joint test on specimen within moisture condition and specimen without moisture, at room temperature. Additionally, this study also analyses the failure stress when load is applied for both exposed conditions. Bulk specimens are compressed at room temperature, specimen without immersing in hot water, RT and specimen with immersing in three hot water conditions 80°C, 90°C, and 100°C at a constant time of 15 minutes. The adhesive of a 1.0mm thickness has been set for T-joint tensile test. Compression test revealed that mechanical properties of Young’s modulus decreased with the increase of water temperature. Experimental results indicated that the failure stress of adhesive T-joint at room temperature and 90°C was higher compared to that of specimen soaked in 80°C and 100°C of hot water. The behaviour of adhesive joint tests under static loading analysis of experiments and the finite element analysis using ANSYS 14.0 software have shown good agreement.

scholarly journals Finite Element Analysis of Ply Orientation Effect on Mechanical Properties of Hybrid Composite Material

2021 ◽  
Author(s):  
Mahesh Gund ◽  
R T Vyavahare
Keyword(s):  
Mechanical Properties ◽  
Composite Material ◽  
Carbon Fiber ◽  
Low Cost ◽  
Research Work ◽  
Natural Fibers ◽  
Weight Ratio ◽  
Coir Fiber ◽  
Banana Plant ◽  
Element Analysis

In recent years, composite material is used as an alternative material for materials like metal, wood, etc. due to low in weight, strength to weight ratio and stiffness properties. Natural fibers like coir fiber, palm fiber, jute fiber, banana plant fiber, etc have low cost, easy availability and less harmful to human body. Also, carbon fiber having various properties such as high strength to weight ratio, rigidity, good tensile strength, fatigue resistance, fire resistance/not flammable, high thermal conductivity. This research work aims to find out the mechanical properties of Carbon fiber, Coir fiber and Epoxy composite material with different ply orientations angles by using FEA software Ansys APDL R15.0.

Classification of Failure Modes in Friction Stir Blind Riveted Lap-Shear Joints With Dissimilar Materials

2016 ◽  
Vol 139 (2) ◽  
Author(s):  
Wei-Ming Wang ◽  
Haris Ali Khan ◽  
Jingjing Li ◽  
Scott F. Miller ◽  
A Zachary Trimble
Keyword(s):  
Failure Modes ◽  
Dissimilar Materials ◽  
Polymeric Composite ◽  
Tensile Tests ◽  
Great Promise ◽  
Lightweight Structures ◽  
Friction Stir ◽  
Lap Shear ◽  
Transportation Sector ◽  
Static Tensile

In transportation sector, there is an increasing need for joining dissimilar materials for lightweight structures; however, substantial barriers to the joining of dissimilar materials have led to an investigation and development of new joining techniques. Friction stir blind riveting (FSBR), a newly invented method, has shown great promise in joining complex structures with dissimilar materials. The process can be utilized more effectively if knowledge regarding the failure mechanisms of the FSBR joints becomes available. This research focuses on investigating the different mechanisms that lead to a failure in FSBR joints under lap-shear tensile tests. An in situ, nondestructive, acoustic emission (AE) testing method was applied during quasi-static tensile tests to monitor the initiation and evolution of damage in FSBR joints with different combinations of dissimilar materials (including aluminum, magnesium, and a carbon-fiber reinforced polymeric composite). In addition, a fractographic analysis was conducted to characterize the failure modes. Finally, based on the analysis, the distinct failure modes and damage accumulation processes for the joints were identified. An AE accumulative hit history curve was found to be efficient to discriminate the deformation characteristics, such as the deformation zone and failure mode, which cannot be observed through a traditional extensometer measurement method. In addition, the AE accumulative hit history curve can be applied to predict the failure extension or moment of FSBR joints through an identification of the changes in curve slope. Such slope changes usually occur around the middle of Zone II, which is defined in this study.

Characterisation and Object-Oriented Finite Element Modelling of Polypropylene/ Organoclay Nanocomposites

2007 ◽  
Vol 334-335 ◽  
pp. 841-844 ◽  
Author(s):  
Y. Dong ◽  
Debes Bhattacharyya ◽  
P.J. Hunter
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Numerical Modelling ◽  
Computational Models ◽  
Research Work ◽  
Weight Ratio ◽  
Object Oriented ◽  
Mechanical Analysis ◽  
Element Analysis ◽  
Maleated Polypropylene

Although much research work has been conducted on the production and characterisation of polypropylene/organoclay nanocomposites, the effects of nanoscale fillers with respect to actual morphology through numerical modelling have been rarely addressed. This paper describes a unique development from fabrication and experimental characterisation to the numerical modelling of polypropylene/organoclay nanocomposites based on the real mapping of nano/microstructures. Twin screw extrusion is used with a two-step masterbatch compounding method to prepare such nanocomposites with organoclays (ranging between 1wt% and 10wt%) and maleated polypropylene (1:1 weight ratio). The material characterisation using X-ray diffraction (XRD), scanning electron microscopy (SEM) and dynamic mechanical analysis (DMTA) are conducted and mechanical properties are determined by tensile, flexural and impact tests. Finally, computational models are established by using an innovative object-oriented finite element analysis code (OOF) to predict the overall mechanical properties of nanocomposites.

scholarly journals Experimental Investigation and Analysis of Tensile Strength of Dissimilar Friction Welded Joints of Aluminium 6061 and Mild Steel

2021 ◽  
Vol 9 (VII) ◽  
pp. 3455-3462
Keyword(s):  
Solid State ◽  
Mild Steel ◽  
Friction Welding ◽  
Research Work ◽  
Engineering Application ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Vital Role ◽  
Rotating Speed ◽  
Joining Process

Nowadays, the joining process plays a vital role in every field of engineering application. Various similar and dissimilar materials are joined by many joining processes to a formed complex component. In all joining processes, welding is a very popular and effective joining process that gives permanent joint. In this process material to be joined is under influence of heat which is produced with aid of external (flame) and internal (friction) mediums. Further, there are types of welding process called friction welding which is solid-state welding, in that process friction had developed between materials having relative motion thus sufficient heat also produced, and welding is performed in solid-state. In recent time’s friction welding is widely used in automobile, aeronautical, structural, marine, etc areas due to its flexibility demand for various materials. In this research work, the aluminium 6061 and mild steel are joined by friction welding by varying the rotating speed of lathe chuck, friction time, burn-off length, and the joint is examined by a tensile test to check its strength. Taguchi’s orthogonal array was used to design the experiment and at the end, the ANOVA test is carried out for the optimization of process parameters.

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