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<p>To investigate the quality of high-strength steel and aluminium alloy clinching joints with unequal thicknesses and the influence of process parameters, clinching experiments were conducted on dissimilar sheet metals using different overlapping methods. A finite element model of non-equal thickness steel-aluminium clinching joints was established to analyze the impact of varying sheet thicknesses and process parameters on the joint quality. The tensile shear tests were performed to measure the strength of the joints. The findings suggest a significant gap inside the joint between the upper aluminium and lower steel, with suboptimal forming quality. The error rate between simulation and experimental results was less than 10%, demonstrating accurate prediction. Optimal joint performance was achieved by utilizing an upper steel sheet (1.3 ~ 1.4 mm) and lower aluminium sheet (1.2 mm) while controlling the bottom thickness at 0.5 mm, resulting in a 14.25% increase in interlock value and a substantial 41.8% increase in neck value. Furthermore, a top steel thickness of 1.0 mm and a bottom aluminium thickness of 1.2 mm exhibited the highest tensile shear force, reaching a maximum tensile strength of 1210 N. The research on clinching unequal thickness high-strength steel and aluminium alloy sheets gives a guide for the lightweight materials connection of the car body.</p>

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Research on the forming quality of clinching joints in clinching of dissimilar steel-aluminium sheet metal with unequal thickness

  • 期刊论文

  • 发表日期：

    2025年2月18日

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  • Song Gao,
  • Xiangjin Liao,
  • Qihan Li,
  • Xianbu Gao,
  • Guotao Wang,
  • Dongwei Gu

摘要

To investigate the quality of high-strength steel and aluminium alloy clinching joints with unequal thicknesses and the influence of process parameters, clinching experiments were conducted on dissimilar sheet metals using different overlapping methods. A finite element model of non-equal thickness steel-aluminium clinching joints was established to analyze the impact of varying sheet thicknesses and process parameters on the joint quality. The tensile shear tests were performed to measure the strength of the joints. The findings suggest a significant gap inside the joint between the upper aluminium and lower steel, with suboptimal forming quality. The error rate between simulation and experimental results was less than 10%, demonstrating accurate prediction. Optimal joint performance was achieved by utilizing an upper steel sheet (1.3 ~ 1.4 mm) and lower aluminium sheet (1.2 mm) while controlling the bottom thickness at 0.5 mm, resulting in a 14.25% increase in interlock value and a substantial 41.8% increase in neck value. Furthermore, a top steel thickness of 1.0 mm and a bottom aluminium thickness of 1.2 mm exhibited the highest tensile shear force, reaching a maximum tensile strength of 1210 N. The research on clinching unequal thickness high-strength steel and aluminium alloy sheets gives a guide for the lightweight materials connection of the car body.