Experimental investigation of the clinching process for joining the three-layer aluminum/polymer/aluminum composite sheets
Three-layer aluminum/polymer/aluminum composite sheets are among the new materials developed to reduce the weight and fuel consumption of vehicles. Using the conventional methods for joining these materials to other materials is challenging. In this paper, the joinability of the three-layer aluminum...
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| Format: | Article |
| Language: | English |
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KeAi Communications Co., Ltd.
2024-03-01
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| Series: | International Journal of Lightweight Materials and Manufacture |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2588840423000513 |
| _version_ | 1797268994383675392 |
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| author | Rasoul Naderli Ali Fazli |
| author_facet | Rasoul Naderli Ali Fazli |
| author_sort | Rasoul Naderli |
| collection | DOAJ |
| description | Three-layer aluminum/polymer/aluminum composite sheets are among the new materials developed to reduce the weight and fuel consumption of vehicles. Using the conventional methods for joining these materials to other materials is challenging. In this paper, the joinability of the three-layer aluminum/polymer/aluminum to a single-layer 1 mm-thickness aluminum sheet, in the clinching process is investigated. Three-layer sheets of AA5754/polyethylene/AA5754 with thicknesses of 0.5/0.6/0.5 mm were produced under laboratory conditions using two different methods; with and without a local reinforcement piece in the polymer core. The prepared specimens are joined using various geometric parameters of the clinching tools. The joint sections and their geometric parameters including interlock and neck thickness are evaluated in different joint conditions. Also, the strengths of the joints are examined by shear and peel tests. Studies show that it is possible to use the clinching process to join aluminum/polymer/aluminum sheets. Also, with a proper design of tools, the joint strength can be in the same order as the strength of the clinching of single-layer sheets. The maximum shear and peel test strengths, obtained in this study are 1288 N and 540 N, respectively. Increasing the pin penetration depth increases the interlock up to an optimal value. However, further increases in the pin penetration depth will decrease the neck thickness and joint strength. The conical angle of the pin, increasing the die cavity depth, and using a local reinforcement piece reduces the strength of the clinched joint and interlock in these materials. In all the test conditions, the most suitable joint conditions were when the failure mode was combined bottom separation and neck fracture mode. |
| first_indexed | 2024-03-08T09:28:05Z |
| format | Article |
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| institution | Directory Open Access Journal |
| issn | 2588-8404 |
| language | English |
| last_indexed | 2024-04-25T01:41:19Z |
| publishDate | 2024-03-01 |
| publisher | KeAi Communications Co., Ltd. |
| record_format | Article |
| series | International Journal of Lightweight Materials and Manufacture |
| spelling | doaj.art-a7bfb1fad1ab4bbdba21224454ca44322024-03-08T05:19:09ZengKeAi Communications Co., Ltd.International Journal of Lightweight Materials and Manufacture2588-84042024-03-0172308326Experimental investigation of the clinching process for joining the three-layer aluminum/polymer/aluminum composite sheetsRasoul Naderli0Ali Fazli1Advanced Forming Technology and Materials Lab, Mechanical Engineering Department, Faculty of Engineering and Technology, Imam Khomeini International University, Qazvin, IranCorresponding author.; Advanced Forming Technology and Materials Lab, Mechanical Engineering Department, Faculty of Engineering and Technology, Imam Khomeini International University, Qazvin, IranThree-layer aluminum/polymer/aluminum composite sheets are among the new materials developed to reduce the weight and fuel consumption of vehicles. Using the conventional methods for joining these materials to other materials is challenging. In this paper, the joinability of the three-layer aluminum/polymer/aluminum to a single-layer 1 mm-thickness aluminum sheet, in the clinching process is investigated. Three-layer sheets of AA5754/polyethylene/AA5754 with thicknesses of 0.5/0.6/0.5 mm were produced under laboratory conditions using two different methods; with and without a local reinforcement piece in the polymer core. The prepared specimens are joined using various geometric parameters of the clinching tools. The joint sections and their geometric parameters including interlock and neck thickness are evaluated in different joint conditions. Also, the strengths of the joints are examined by shear and peel tests. Studies show that it is possible to use the clinching process to join aluminum/polymer/aluminum sheets. Also, with a proper design of tools, the joint strength can be in the same order as the strength of the clinching of single-layer sheets. The maximum shear and peel test strengths, obtained in this study are 1288 N and 540 N, respectively. Increasing the pin penetration depth increases the interlock up to an optimal value. However, further increases in the pin penetration depth will decrease the neck thickness and joint strength. The conical angle of the pin, increasing the die cavity depth, and using a local reinforcement piece reduces the strength of the clinched joint and interlock in these materials. In all the test conditions, the most suitable joint conditions were when the failure mode was combined bottom separation and neck fracture mode.http://www.sciencedirect.com/science/article/pii/S2588840423000513Clinching processThree-layer aluminum/polymer/aluminum sheetTool geometryLocal reinforcement pieceJoining by forming |
| spellingShingle | Rasoul Naderli Ali Fazli Experimental investigation of the clinching process for joining the three-layer aluminum/polymer/aluminum composite sheets International Journal of Lightweight Materials and Manufacture Clinching process Three-layer aluminum/polymer/aluminum sheet Tool geometry Local reinforcement piece Joining by forming |
| title | Experimental investigation of the clinching process for joining the three-layer aluminum/polymer/aluminum composite sheets |
| title_full | Experimental investigation of the clinching process for joining the three-layer aluminum/polymer/aluminum composite sheets |
| title_fullStr | Experimental investigation of the clinching process for joining the three-layer aluminum/polymer/aluminum composite sheets |
| title_full_unstemmed | Experimental investigation of the clinching process for joining the three-layer aluminum/polymer/aluminum composite sheets |
| title_short | Experimental investigation of the clinching process for joining the three-layer aluminum/polymer/aluminum composite sheets |
| title_sort | experimental investigation of the clinching process for joining the three layer aluminum polymer aluminum composite sheets |
| topic | Clinching process Three-layer aluminum/polymer/aluminum sheet Tool geometry Local reinforcement piece Joining by forming |
| url | http://www.sciencedirect.com/science/article/pii/S2588840423000513 |
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