@inbook{34209,
abstract = {{Predicting the durability of components subjected to mechanical load under environmental conditions leading to corrosion is one of the most challenging tasks in mechanical engineering. The demand for precise predictions increases with the desire of lightweight design in transportation due to environmental protection. Corrosion with its manifold of mechanisms often occurs together with the production of hydrogen by electrochemical reactions. Hydrogen embrittlement is one of the most feared damage mechanisms for metal constructions often leading to early and unexpected failure. Until now, predictions are mostly based on costly experiments. Hence, a rational predictive model based on the fundamentals of electrochemistry and damage mechanics has to be developed in order to reduce the costs. In this work, a first model approach based on classical continuum damage mechanics is presented to couple both, the damage induced by the mechanical stress and the hydrogen embrittlement. An elaborated two-scale model based on the selfconsistent theory is applied to describe the mechanical damage due to fatigue. The electrochemical kinetics are elucidated through the Langmuir adsorption isotherm and the diffusion equation to consider the impact of hydrogen embrittlement on the fatigue. The modeling of the mechanism of hydrogen embrittlement defines the progress of damage accumulation due to the electrochemistry. The durability results like the S-N diagram show the influence of hydrogen embrittlement by varying, e.g. the fatigue frequency or the stress ratio.}},
author = {{Shi, Yuhao and Harzheim, Sven and Hofmann, Martin and Wallmersperger, Thomas}},
booktitle = {{Material Modeling and Structural Mechanics}},
isbn = {{9783030976743}},
issn = {{1869-8433}},
keywords = {{Hydrogen embrittlement, Fatigue, Continuum damage mechanics, Numerical simulation, Multi-field problem}},
publisher = {{Springer International Publishing}},
title = {{{A Damage Model for Corrosion Fatigue Due to Hydrogen Embrittlement}}},
doi = {{10.1007/978-3-030-97675-0_9}},
year = {{2022}},
}
@article{34251,
abstract = {{Joining by forming operations presents powerful and complex joining techniques. Clinching is a well-known joining process for use in sheet metalworking. Currently, clinched joints are focusing on mechanically enhanced connections. Additionally, the demand for integrating electrical requirements to transmit electrical currents will be increased in the future. This integration is particularly important, for instance, in the e-mobility sector. It enables connecting battery cells with electrical joints of aluminum and copper. Systematic use of the process-specific advantages of this joining method opens up the possibility to find and create electrically optimized connections. The optimization for the transmission of electrical currents will be demonstrated for clinched joints by adapting the tool geometry and the clinched joint design. Based on a comparison of the electrical joint resistance, the limit use temperature is defined for the joining materials used based on the microstructural condition and the aging condition due to artificial aging. As a result of the investigations carried out, reliable current transmission at a constant conductor temperature of up to 120 °C can be achieved for clinched copper–copper joints. In the case of pure aluminum joints and mixed joints of aluminum and copper, long-term stable current transmission can be ensured up to a conductor temperature of 100 °C.}},
author = {{Kalich, Jan and Matzke, Marcus and Pfeiffer, Wolfgang and Schlegel, Stephan and Kornhuber, Ludwig and Füssel, Uwe}},
issn = {{2075-4701}},
journal = {{Metals}},
keywords = {{General Materials Science, Metals and Alloys}},
number = {{10}},
publisher = {{MDPI AG}},
title = {{{Long-Term Behavior of Clinched Electrical Contacts}}},
doi = {{10.3390/met12101651}},
volume = {{12}},
year = {{2022}},
}
@article{34254,
abstract = {{A virtual test setup for investigating single fibres in a transverse shear flow based on a parallel-plate rheometer is presented. The investigations are carried out to verify a numerical representation of the fluid–structure interaction (FSI), where Arbitrary Lagrangian–Eulerian (ALE) and computational fluid dynamics (CFD) methods are used and evaluated. Both are suitable to simulate flexible solid structures in a transverse shear flow. Comparative investigations with different model setups and increasing complexity are presented. It is shown, that the CFD method with an interface-based coupling approach is not capable of handling small fibre diameters in comparison to large fluid domains due to mesh dependencies at the interface definitions. The ALE method is more suited for this task since fibres are embedded without any mesh restrictions. Element types beam, solid, and discrete are considered for fibre modelling. It is shown that the beam formulation for ALE and 3D solid elements for the CFD method are the preferred options.}},
author = {{Gröger, Benjamin and Wang, Jingjing and Bätzel, Tim and Hornig, Andreas and Gude, Maik}},
issn = {{1996-1944}},
journal = {{Materials}},
keywords = {{General Materials Science}},
number = {{20}},
publisher = {{MDPI AG}},
title = {{{Modelling and Simulation Strategies for Fluid–Structure-Interactions of Highly Viscous Thermoplastic Melt and Single Fibres—A Numerical Study}}},
doi = {{10.3390/ma15207241}},
volume = {{15}},
year = {{2022}},
}
@article{34257,
abstract = {{Galvanic corrosion is a destructive process between dissimilar metals. The present paper presents a constructed numerical test case to simulate galvanic corrosion of two dissimilar metals. This test case is used to study the accuracy of different implementations to track the dissolving anode boundary. One technique is to numerically simulate a mesh displacement based on the prescribed displacement at the anode boundary. The second method is to adjust only the boundary elements. Re-meshing after a certain number of time steps is applied to both implementations. They produce similar results for an electrical and electrochemical field problem. This work shows that mesh smoothing does not result in higher accuracy when modeling a moving anode front. Adjusting only the boundary elements is sufficient when frequent re-meshing is used.}},
author = {{Harzheim, Sven and Hofmann, Martin and Wallmersperger, Thomas}},
issn = {{0001-5970}},
journal = {{Acta Mechanica}},
keywords = {{Mechanical Engineering, Computational Mechanics}},
number = {{11}},
pages = {{4427--4439}},
publisher = {{Springer Science and Business Media LLC}},
title = {{{Comparison of two mesh-moving techniques for finite element simulations of galvanic corrosion}}},
doi = {{10.1007/s00707-022-03326-z}},
volume = {{233}},
year = {{2022}},
}
@inproceedings{34250,
abstract = {{As a joining-by-forming process, clinching and the use of functional elements enable low-energy joining of components through form, force, and, under certain conditions, material closure. In addition to the transmission of mechanical forces, these joining processes can be qualified for additional electrical contact within the scope of functional integration for electro-mobile applications. For this purpose, maximizing the force and material closure is necessary to ensure a long-term, stable transmission of electrical currents. To this end, the electrical properties of the joints were optimized. The investigations carried out show the long-term behavior under normal operating conditions and the short-circuit case.}},
author = {{Füssel, Uwe and Schlegel, Stephan and Reschke, Gregor and Kalich, Jan}},
booktitle = {{SFU/ICAFT 2022}},
publisher = {{MDPI}},
title = {{{Electrical Contacting of Aluminum Bus Bars Using Clinching and Functional Elements}}},
doi = {{10.3390/engproc2022026005}},
year = {{2022}},
}
@inproceedings{34280,
abstract = {{Clinching is a cost efficient method for joining components in series production. To assure the clinch point’s quality, the force displacement curve during clinching or the bottom thickness are monitored. The most significant geometrical characteristics of the clinch point, neck thickness and undercut, are usually tested destructively by microsectioning. However, micrograph preparation goes ahead with a resetting of elastic deformations and crack-closing after unloading. To generate a comprehensive knowledge of the clinch point’s inner geometry under load, in-situ computed tomography (CT) and acoustic testing (TDA) can be combined. While the TDA is highly sensitive to the inner state of the clinch point, it could detect critical events like crack development during loading. If such events are indicated, the loading process is stopped and a stepped in-situ CT of the following crack and deformation development is performed. In this paper, the concept is applied to the process of clinching itself, providing a detailed three-dimensional insight in the development of the joining zone. A test set-up is used which allows a stepwise clinching of two aluminium sheets EN AW 6014. Furthermore, this set-up is positioned within a CT system. In order to minimize X-ray absorption, a beryllium cylinder is used within the set-up frame and clinching tools are made from Si3N4. The actuator and sensor necessary for the TDA are integrated in the set-up. In regular process steps, the clinching process is interrupted in order to perform a TDA and a CT scan. In order to enhance the visibility of the interface, a thin tin layer is positioned between the sheets prior clinching. It is shown, that the test-set up allows a monitoring of the dynamic behaviour of the specimen during clinching while the CT scans visualize the inner geometry and material flow non-destructively.}},
author = {{Köhler, Daniel and Stephan, Richard and Kupfer, Robert and Troschitz, Juliane and Brosius, Alexander and Gude, Maik}},
booktitle = {{Key Engineering Materials}},
issn = {{1662-9795}},
keywords = {{Mechanical Engineering, Mechanics of Materials, General Materials Science}},
pages = {{1489--1497}},
publisher = {{Trans Tech Publications, Ltd.}},
title = {{{Investigations on Combined in situ CT and Acoustic Analysis during Clinching}}},
doi = {{10.4028/p-32330d}},
volume = {{926}},
year = {{2022}},
}
@article{34414,
abstract = {{Given a steadily increasing demand on multi-material lightweight designs, fast and cost-efficient production technologies, such as the mechanical joining process clinching, are becoming more and more relevant for series production. Since the application of such joining techniques often base on the ability to reach similar or even better joint loading capacities compared to established joining processes (e.g., spot welding), few contributions investigated the systematic improvement of clinch joint characteristics. In this regard, the use of data-driven methods in combination with optimization algorithms showed already high potentials for the analysis of individual joints and the definition of optimal tool configurations. However, the often missing consideration of uncertainties, such as varying material properties, and the related calculation of their impact on clinch joint properties can lead to poor estimation results and thus to a decreased reliability of the entire joint connection. This can cause major challenges, especially for the design and dimensioning of safety-relevant components, such as in car bodies. Motivated by this, the presented contribution introduces a novel method for the robust estimation of clinch joint characteristics including uncertainties of varying and versatile process chains in mechanical joining. Therefore, the utilization of Gaussian process regression models is demonstrated and evaluated regarding the ability to achieve sufficient prediction qualities.}},
author = {{Zirngibl, Christoph and Schleich, Benjamin and Wartzack, Sandro}},
issn = {{0268-3768}},
journal = {{The International Journal of Advanced Manufacturing Technology}},
keywords = {{Industrial and Manufacturing Engineering, Computer Science Applications, Mechanical Engineering, Software, Control and Systems Engineering}},
publisher = {{Springer Science and Business Media LLC}},
title = {{{Robust estimation of clinch joint characteristics based on data-driven methods}}},
doi = {{10.1007/s00170-022-10441-7}},
year = {{2022}},
}
@article{34261,
abstract = {{Mechanical clinching is used to create lightweight hybrid structures. In order to estimate the service life of clinched components, its fatigue properties need to be known under different mechanical loading conditions. In addition to fatigue, corrosion is another factor that affects the fatigue life of clinched joints. In the literature, many corrosion and high-cycle fatigue damage models exist. However, little is known about how both phenomena interact in clinched joints. In this article, the influence of galvanic corrosion on clinched EN AW-6014/HCT590X + Z sheets on the fatigue life is investigated by means of numerical simulations and experimental results. An accurate prediction of the Wöhler lines of non-corroded and pre-corroded clinched specimens is shown.}},
author = {{Harzheim, Sven and Hofmann, Martin and Wallmersperger, Thomas}},
issn = {{1537-6494}},
journal = {{Mechanics of Advanced Materials and Structures}},
keywords = {{Mechanical Engineering, Mechanics of Materials, General Materials Science, General Mathematics, Civil and Structural Engineering}},
pages = {{1--6}},
publisher = {{Informa UK Limited}},
title = {{{Numerical fatigue life prediction of corroded and non-corroded clinched joints}}},
doi = {{10.1080/15376494.2022.2140233}},
year = {{2022}},
}
@inproceedings{36462,
abstract = {{The conduction of structure-borne sound through joints causes energy dissipation. The sound reduction index describes this energy loss as a level decrease in the particle velocity across series-connected damping elements for which the superposition principle applies. This simple model can help to develop a testing method for joints based on this characteristic energy loss. In this paper, this model is experimentally evaluated for multiple in-series clinched aluminium sheets. Samples connected by several clinch points arranged in parallel are investigated experimentally, and the results are discussed.}},
author = {{Stephan, Richard and Brosius, Alexander}},
booktitle = {{The 28th Saxon Conference on Forming Technology SFU and the 7th International Conference on Accuracy in Forming Technology ICAFT}},
keywords = {{clinching, mechanical joining, damping, model, evaluation, dynamics}},
publisher = {{MDPI}},
title = {{{Experimental Measurement Method and Evaluation of an Analytical Approach for Sound Conduction through Multiple Clinched Sheets}}},
doi = {{10.3390/engproc2022026025}},
year = {{2022}},
}
@inproceedings{36468,
author = {{Römisch, David and Merklein, Marion}},
location = {{Örebro}},
title = {{{Experimental and Numerical Analysis of Cold Formed Multi Pin Structures Using a Multi-Acting Tool Design}}},
year = {{2022}},
}
@inproceedings{36470,
author = {{Wituschek, Simon and Lechner, Michael}},
title = {{{Versatile tool design for a tumbling self-piercing riveting process}}},
year = {{2022}},
}
@inproceedings{36473,
abstract = {{Destructive micrograph analysis (MA) is the standard method for the assessment of clinched joints. However, during the joint preparation for the MA, geometric features of the joint can change due to elastic effects and closing cracks. X-ray computed tomography (CT) is a promising alternative to investigate the joint non-destructively. However, if the
material properties of similar joining partners are the same, the CT is not able to correctly resolve surfaces in the joint that are close to or pressing onto each other. These surfaces are relevant for the determination of characteristic dimensions such as neck thickness and undercut. By placing a thin, highly radiopaque tin layer between the joining partners, the interfacial area in the reconstructed volume can be highlighted. In this work, a method for the localisation of the tin layer inside the joint as well as threshold value procedures for the outer joint contour in cross section images are investigated. The measured characteristic dimensions are compared with measured values from MA of the same samples and of samples without tin layer. In addition, possible effects of the tin layer on the joining point
characteristics as well as problems of the MA are discussed.}},
author = {{Busch, Matthias and Köhler, Daniel and Hausotte, Tino and Kupfer, Robert and Troschitz, Juliane and Gude, Maik }},
title = {{{Approach to Determine the Characteristic Dimensions of Clinched Joints by Industrial X-ray Computed Tomography}}},
year = {{2022}},
}
@article{29724,
abstract = {{ In many manufacturing areas, multi-material designs are implemented in which individual components are joined together to form complex structures with numerous joints. For example, in the automotive sector, cast components are used at the junctions of the body and joined with different types of sheet metal and extruded profiles. To be able to join structures consisting of different materials, alternative joining technologies have emerged in recent years. This includes clinching, which allows assembling of two or more thin sheet metal and casting parts by solely cold forming the material. Clinching the brittle and usually less ductile cast aluminium alloys remains a challenge because the brittle character of the cast aluminium alloys can cause cracks during the forming of the clinched joint. In this study, the influence of the heat treatment time of an aluminium casting alloy AlSi9 on the joinability in the clinching process is investigated. Specific heat treatment of the naturally hard AlSi9 leads to a modification of the eutectic microstructure, which can increase ductility. Based on this, it will be examined if specific clinching die geometries can be used, which achieve an optimized geometrical formation of the clinched joint. The load-bearing capacities of the clinched joints are determined and compared by shear tensile and head tensile tests. Furthermore, the joints are examined microscopically to investigate the influence of the heat treatment on the failure behaviour during the load-bearing tests as well as crack initiation within the joining process. }},
author = {{Neuser, Moritz and Böhnke, Max and Grydin, Olexandr and Bobbert, Mathias and Schaper, Mirko and Meschut, Gerson}},
issn = {{1464-4207}},
journal = {{Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications}},
keywords = {{Mechanical Engineering, General Materials Science}},
publisher = {{SAGE Publications}},
title = {{{Influence of heat treatment on the suitability for clinching of the aluminium casting alloy AlSi9}}},
doi = {{10.1177/14644207221075838}},
year = {{2022}},
}
@article{29505,
abstract = {{In modern vehicle chassis, multi-material design is implemented to apply the appropriate material for each functionality. In spaceframe technology, both sheet metal and continuous cast are joined to castings at the nodal points of the chassis. Since resistance spot welding is not an option when different materials are joined, research is focusing on mechanical joining methods for multi-material designs. To reduce weight and achieve the required strength, hardenable cast aluminium alloys of the AlSi-system are widely used. Thus, 85–90% of aluminium castings in the automotive industry are comprised of the AlSi-system. Due to the limited weldability, mechanical joining is a suitable process. For this application, various optimisation strategies are required to produce a crack-free joint, as the brittle character of the AlSi alloy poses a challenge. Thus, adapted castings with appropriate ductility are needed. Hence, in this study, the age-hardenable cast aluminium alloy AlSi10Mg is investigated regarding the correlation of the different thicknesses, the microstructural characteristics as well as the resulting mechanical properties. A variation of the thicknesses leads to different solidification rates, which in turn affect the microstructure formation and are decisive for the mechanical properties of the casting as well as the joinability. For the investigation, plates with thicknesses from 2.0 to 4.0 mm, each differing by 0.5 mm, are produced via sand casting. Hence, the overall aim is to evaluate the joinability of AlSi10Mg and derive conclusions concerning the microstructure and mechanical properties.}},
author = {{Neuser, Moritz and Grydin, Olexandr and Frolov, Y. and Schaper, Mirko}},
issn = {{0944-6524}},
journal = {{Production Engineering}},
keywords = {{Industrial and Manufacturing Engineering, Mechanical Engineering}},
publisher = {{Springer Science and Business Media LLC}},
title = {{{Influence of solidification rates and heat treatment on the mechanical performance and joinability of the cast aluminium alloy AlSi10Mg}}},
doi = {{10.1007/s11740-022-01106-1}},
year = {{2022}},
}
@inbook{29771,
author = {{Grydin, Olexandr and Mortensen, Dag and Neuser, Moritz and Lindholm, Dag and Fjaer, Hallvard G. and Schaper, Mirko}},
booktitle = {{Light Metals 2022}},
isbn = {{9783030925284}},
issn = {{2367-1181}},
publisher = {{Springer International Publishing}},
title = {{{Numerical and Experimental Investigation of Heat Transfer in the Solidification-Deformation Zone During Twin-Roll Casting of Aluminum Strips}}},
doi = {{10.1007/978-3-030-92529-1_96}},
year = {{2022}},
}
@article{34215,
abstract = {{Clinching as a mechanical joining technique allows a fast and reliable joining of metal sheets in large-scale production. An efficient design and dimensioning of clinched joints requires a holistic understanding of the material, the joining process and the resulting properties of the joint. In this paper, the process chain for clinching metal sheets is described and experimental techniques are proposed to analyze the process-microstructure-property relationships from the sheet metal to the joined structure. At the example of clinching aluminum EN AW 6014, characterization methods are applied and discussed for the following characteristics: the mechanical properties of the sheet materials, the tribological behavior in the joining system, the joining process and the resulting material structure, the load-bearing behavior of the joint, the damage and degradation as well as the service life and crack growth behavior. The compilation of the characterization methods gives an overview on the advantages and weaknesses of the methods and the multiple interactions of material, process and properties during clinching. In addition, the results of the analyses on EN AW 6014 can be applied for parameterization and validation of simulations.}},
author = {{Kupfer, Robert and Köhler, Daniel and Römisch, David and Wituschek, Simon and Ewenz, Lars and Kalich, Jan and Weiß, Deborah and Sadeghian, Behdad and Busch, Matthias and Krüger, Jan Tobias and Neuser, Moritz and Grydin, Olexandr and Böhnke, Max and Bielak, Christian Roman and Troschitz, Juliane}},
issn = {{2666-3309}},
journal = {{Journal of Advanced Joining Processes}},
keywords = {{Mechanical Engineering, Mechanics of Materials, Engineering (miscellaneous), Chemical Engineering (miscellaneous)}},
publisher = {{Elsevier BV}},
title = {{{Clinching of Aluminum Materials – Methods for the Continuous Characterization of Process, Microstructure and Properties}}},
doi = {{10.1016/j.jajp.2022.100108}},
volume = {{5}},
year = {{2022}},
}
@article{34264,
abstract = {{In industrial x-ray computed tomography (CT), the application of more complex scan paths in comparison to the typical circular trajectory (${360}^{\circ}$ rotation of the measurement object) can extend the potential of CT. One way to enable such 3D scan trajectories is to use a 6-degrees-of-freedom (DOF) object manipulator system. In our case, a hexapod is mounted on top of the rotary table of a commercial CT scanner. This allows for adaptive tilting of the measurement object during the scan. For high accuracy, the geometry calibration of such setups is typically done using the x-ray projections of a calibrated multi-sphere object. Contrary to this, here, we demonstrate a procedure that is based on only a single sphere and can therefore experimentally be implemented with low effort. Using the intrinsic geometry parameters of the CT device as prior information, the hexapod coordinate system with respect to the CT machine coordinate system is determined by means of a one-step optimization approach. The resulting parameters are used to calculate projection matrices that enable the volume reconstruction for 3D scan trajectories. The method is validated using simulated x-ray images and experimental investigations including dimensional measurements. For the used setup, geometric measurement results for 3D scan trajectories that are calibrated with the presented method show in sum increased errors compared to the circular scans. A limited pose accuracy of the manipulator system is discussed as a potential cause. The results nevertheless indicate that the presented method is generally feasible for dimensional CT measurements provided that the pose accuracy is sufficient. The calibration procedure can therefore be a low-cost and easier to implement alternative compared to trajectory calibration methods based on multi-sphere objects, but with a tendency towards lower measurement accuracy. The methodology can in principle be transferred to different setups with 6-DOF manipulator systems, e.g. C-arm CT devices with a robot arm.}},
author = {{Butzhammer, Lorenz and Müller, Andreas Michael and Hausotte, Tino}},
issn = {{0957-0233}},
journal = {{Measurement Science and Technology}},
keywords = {{Applied Mathematics, Instrumentation, Engineering (miscellaneous)}},
number = {{1}},
publisher = {{IOP Publishing}},
title = {{{Calibration of 3D scan trajectories for an industrial computed tomography setup with 6-DOF object manipulator system using a single sphere}}},
doi = {{10.1088/1361-6501/ac9856}},
volume = {{34}},
year = {{2022}},
}
@article{33002,
abstract = {{Many mechanical material properties show a dependence on the strain rate, e.g. yield stress or elongation at fracture. The quantitative description of the material behavior under dynamic loading is of major importance for the evaluation of crash safety. This is carried out using numerical methods and requires characteristic values for the materials used. For the standardized determination of dynamic characteristic values in sheet metal materials, tensile tests performed according to the guideline from [1]. A particular challenge in dynamic tensile tests is the force measurement during the test. For this purpose, strain gauges are attached on each specimen, wired to the measuring equipment and calibrated. This is a common way to determine a force signal that is as low in vibration and as free of bending moments as possible. The preparation effort for the used strain gauges are enormous. For these reasons, an optical method to determine the force by strain measurement using DIC is presented. The experiments are carried out on a high speed tensile testing system. In combioantion with a 3D DIC high speed system for optical strain measurement. The elastic deformation of the specimen in the dynamometric section is measured using strain gauges and the optical method. The measured signals are then compared to validate the presented method. The investigations are conducted using the dual phase steel material HCT590X and the aluminum material EN AW-6014 T4. Strain rates of up to 240 s-1 are investigated.}},
author = {{Böhnke, Max and Unruh, Eduard and Sell, Stanislaw and Bobbert, Mathias and Hein, David and Meschut, Gerson}},
issn = {{1662-9795}},
journal = {{Key Engineering Materials}},
keywords = {{Mechanical Engineering, Mechanics of Materials, General Materials Science}},
location = {{Braga, Portugal}},
pages = {{1564--1572}},
publisher = {{Trans Tech Publications, Ltd.}},
title = {{{Functionality Study of an Optical Measurement Concept for Local Force Signal Determination in High Strain Rate Tensile Tests}}},
doi = {{10.4028/p-wpuzyw}},
volume = {{926}},
year = {{2022}},
}
@inbook{33003,
author = {{Böhnke, Max and Bielak, Christian Roman and Bobbert, Mathias and Meschut, Gerson}},
booktitle = {{The Minerals, Metals & Materials Series}},
isbn = {{9783031062117}},
issn = {{2367-1181}},
location = {{Toronto, Kanada}},
publisher = {{Springer International Publishing}},
title = {{{Development of a Modified Punch Test for Investigating the Failure Behavior in Sheet Metal Materials}}},
doi = {{10.1007/978-3-031-06212-4_52}},
year = {{2022}},
}
@article{31360,
abstract = {{The adaptive joining process employing friction-spun joint connectors (FSJC) is a promising method for the realization of adaptable joints and thus for lightweight construction. In addition to experimental investigations, numerical studies are indispensable tools for its development. Therefore, this paper includes an analysis of boundary conditions for the spatial discretization and mesh modeling techniques, the material modeling, the contact and friction modeling, and the thermal boundary conditions for the finite element (FE) modeling of this joining process. For these investigations, two FE models corresponding to the two process steps were set up and compared with the two related processes of friction stir welding and friction drilling. Regarding the spatial discretization, the Lagrangian approach is not sufficient to represent the deformation that occurs. The Johnson-Cook model is well suited as a material model. The modeling of the contact detection and friction are important research subjects. Coulomb’s law of friction is not adequate to account for the complex friction phenomena of the adaptive joining process. The thermal boundary conditions play a decisive role in heat generation and thus in the material flow of the process. It is advisable to use temperature-dependent parameters and to investigate in detail the influence of radiation in the entire process.}},
author = {{Oesterwinter, Annika and Wischer, Christian and Homberg, Werner}},
issn = {{2075-4701}},
journal = {{Metals}},
keywords = {{General Materials Science, Metals and Alloys}},
number = {{5}},
publisher = {{MDPI AG}},
title = {{{Identification of Requirements for FE Modeling of an Adaptive Joining Technology Employing Friction-Spun Joint Connectors (FSJC)}}},
doi = {{10.3390/met12050869}},
volume = {{12}},
year = {{2022}},
}