---
_id: '54797'
abstract:
- lang: eng
text: Focusing on upcoming challenges in lightweight design, such as increasing
emission targets or novel multimaterial connections, versatile applicable and
environmentally friendly production technologies are crucial. In this context,
mechanical joining technology clinching offers a fast and energy-efficient procedure
for assembling sheet metals, being a proper alternative to established joining
methods, such as spot welding. However, the design of clinch points is a challenge,
which is partly supported by numerical or data-based approaches for optimal tool
dimensions assuring proper joint characteristics. While this is usually done for
an ideal environment, real joining processes are characterized by multiple inevitably
varying parameters, e.g. of the material, which have a significant impact on the
quality of clinch points. Therefore, this contribution addresses the current gap
by analyzing the effect of parameter variations or uncertainties on the resulting
joint characteristics and studying the impact of the nominal tool design. Thus,
an efficient meta-model-based variation simulation procedure is proposed and used
for analyzing the effect of different tool design configurations and variation
scenarios. Based on the results, it was found that varying process parameters
have a strong impact on the resulting joint characteristics, whereby the effect
significantly depends on the nominal tool design. This reveals the potential for
a robust tool design and implies that the nominal tool design and the tolerancing
of parameters should be done simultaneously for a reliable virtual joining point
design without extensive iterations and physical tests.
author:
- first_name: C
full_name: Zirngibl, C
last_name: Zirngibl
- first_name: S
full_name: Goetz, S
last_name: Goetz
- first_name: S
full_name: Wartzack, S
last_name: Wartzack
citation:
ama: 'Zirngibl C, Goetz S, Wartzack S. Influence of process variations on clinch
joint characteristics considering the effect of the nominal tool design. Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering. Published online 2024. doi:10.1177/09544089241259347'
apa: 'Zirngibl, C., Goetz, S., & Wartzack, S. (2024). Influence of process variations
on clinch joint characteristics considering the effect of the nominal tool design.
Proceedings of the Institution of Mechanical Engineers, Part E: Journal of
Process Mechanical Engineering. https://doi.org/10.1177/09544089241259347'
bibtex: '@article{Zirngibl_Goetz_Wartzack_2024, title={Influence of process variations
on clinch joint characteristics considering the effect of the nominal tool design},
DOI={10.1177/09544089241259347},
journal={Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering}, publisher={SAGE Publications}, author={Zirngibl,
C and Goetz, S and Wartzack, S}, year={2024} }'
chicago: 'Zirngibl, C, S Goetz, and S Wartzack. “Influence of Process Variations
on Clinch Joint Characteristics Considering the Effect of the Nominal Tool Design.”
Proceedings of the Institution of Mechanical Engineers, Part E: Journal of
Process Mechanical Engineering, 2024. https://doi.org/10.1177/09544089241259347.'
ieee: 'C. Zirngibl, S. Goetz, and S. Wartzack, “Influence of process variations
on clinch joint characteristics considering the effect of the nominal tool design,”
Proceedings of the Institution of Mechanical Engineers, Part E: Journal of
Process Mechanical Engineering, 2024, doi: 10.1177/09544089241259347.'
mla: 'Zirngibl, C., et al. “Influence of Process Variations on Clinch Joint Characteristics
Considering the Effect of the Nominal Tool Design.” Proceedings of the Institution
of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering,
SAGE Publications, 2024, doi:10.1177/09544089241259347.'
short: 'C. Zirngibl, S. Goetz, S. Wartzack, Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering (2024).'
date_created: 2024-06-18T07:00:26Z
date_updated: 2024-06-18T07:06:38Z
department:
- _id: '630'
doi: 10.1177/09544089241259347
language:
- iso: eng
project:
- _id: '130'
grant_number: '418701707'
name: 'TRR 285: TRR 285'
- _id: '132'
name: 'TRR 285 - B: TRR 285 - Project Area B'
- _id: '144'
name: 'TRR 285 – B05: TRR 285 - Subproject B05'
publication: 'Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering'
publication_identifier:
issn:
- 0954-4089
- 2041-3009
publication_status: published
publisher: SAGE Publications
status: public
title: Influence of process variations on clinch joint characteristics considering
the effect of the nominal tool design
type: journal_article
user_id: '107109'
year: '2024'
...
---
_id: '56083'
abstract:
- lang: eng
text: The increasing significance of ecological responsibility, stricter
political regulations and economic objectives are driving innovation in research
fields such as lightweight construction. One of the most important popular methods
is the use of multi-material systems. Due to the different geometric and mechanical
properties of the various materials used, resource efficient applications and
utilizations are possible. Great challenges arise for the joining processes to
realize these multi-material systems, since conventional joining processes reach
their limits. In the field of mechanical joining processes, there are continuously
new approaches, such as superimposing the punch in a self-piercing riveting process
with a tumbling kinematic, to increase the number of adaptable process parameters
and enhance the process control. Through various preliminary tests, a good understanding
of the process has been developed, which allows to directly control the geometric
joint parameters by configuring the tumbling strategy. A major challenge, particularly
with regard to future industrial applications, is the process time, which is comparatively
high due to the tumbling kinematics. In the investigations, a reduction of approximately
90% of the process time is targeted by adapting the joining and tumbling strategy.
Therefore, the correlation of the traverse velocity and the tumbling velocity
are examined in a gradual series of experiments. To represent realistic applications,
the experiments are carried out with a dual-phase steel and a precipitation-hardening
aluminum alloy. For identifying the influence of the process parameters on the
joining process, a constant rivet–die combination is applied. Further, the examination
of force–displacement curves is conducted. Moreover, the determination of geometric
joint parameters is reliant upon macrographs to assess the influence of the joining
time on the geometric joint formation. The test results show that a significant
increase in joining speed with a resulting reduction in process time is feasible.
Although the joining properties are affected, reliable joining is possible. In
particular, the shaft thickness of the rivet is influenced by the varying proportion
of the tumbling process in the joining operation and increases with higher joining
speeds.
author:
- first_name: Simon
full_name: Wituschek, Simon
last_name: Wituschek
- first_name: Leonie
full_name: Elbel, Leonie
last_name: Elbel
- first_name: Michael
full_name: Lechner, Michael
last_name: Lechner
citation:
ama: 'Wituschek S, Elbel L, Lechner M. Influence of the process time on a self-piercing
riveting process with tumbling kinematic. Proceedings of the Institution of
Mechanical Engineers, Part E: Journal of Process Mechanical Engineering. Published
online 2024. doi:10.1177/09544089241248430'
apa: 'Wituschek, S., Elbel, L., & Lechner, M. (2024). Influence of the process
time on a self-piercing riveting process with tumbling kinematic. Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering. https://doi.org/10.1177/09544089241248430'
bibtex: '@article{Wituschek_Elbel_Lechner_2024, title={Influence of the process
time on a self-piercing riveting process with tumbling kinematic}, DOI={10.1177/09544089241248430},
journal={Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering}, publisher={SAGE Publications}, author={Wituschek,
Simon and Elbel, Leonie and Lechner, Michael}, year={2024} }'
chicago: 'Wituschek, Simon, Leonie Elbel, and Michael Lechner. “Influence of the
Process Time on a Self-Piercing Riveting Process with Tumbling Kinematic.” Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering, 2024. https://doi.org/10.1177/09544089241248430.'
ieee: 'S. Wituschek, L. Elbel, and M. Lechner, “Influence of the process time on
a self-piercing riveting process with tumbling kinematic,” Proceedings of the
Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering,
2024, doi: 10.1177/09544089241248430.'
mla: 'Wituschek, Simon, et al. “Influence of the Process Time on a Self-Piercing
Riveting Process with Tumbling Kinematic.” Proceedings of the Institution of
Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, SAGE
Publications, 2024, doi:10.1177/09544089241248430.'
short: 'S. Wituschek, L. Elbel, M. Lechner, Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering (2024).'
date_created: 2024-09-06T08:07:41Z
date_updated: 2024-09-06T08:10:50Z
doi: 10.1177/09544089241248430
language:
- iso: eng
publication: 'Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering'
publication_identifier:
issn:
- 0954-4089
- 2041-3009
publication_status: published
publisher: SAGE Publications
status: public
title: Influence of the process time on a self-piercing riveting process with tumbling
kinematic
type: journal_article
user_id: '83423'
year: '2024'
...
---
_id: '56084'
abstract:
- lang: eng
text: The increasing significance of ecological responsibility, stricter
political regulations and economic objectives are driving innovation in research
fields such as lightweight construction. One of the most important popular methods
is the use of multi-material systems. Due to the different geometric and mechanical
properties of the various materials used, resource efficient applications and
utilizations are possible. Great challenges arise for the joining processes to
realize these multi-material systems, since conventional joining processes reach
their limits. In the field of mechanical joining processes, there are continuously
new approaches, such as superimposing the punch in a self-piercing riveting process
with a tumbling kinematic, to increase the number of adaptable process parameters
and enhance the process control. Through various preliminary tests, a good understanding
of the process has been developed, which allows to directly control the geometric
joint parameters by configuring the tumbling strategy. A major challenge, particularly
with regard to future industrial applications, is the process time, which is comparatively
high due to the tumbling kinematics. In the investigations, a reduction of approximately
90% of the process time is targeted by adapting the joining and tumbling strategy.
Therefore, the correlation of the traverse velocity and the tumbling velocity
are examined in a gradual series of experiments. To represent realistic applications,
the experiments are carried out with a dual-phase steel and a precipitation-hardening
aluminum alloy. For identifying the influence of the process parameters on the
joining process, a constant rivet–die combination is applied. Further, the examination
of force–displacement curves is conducted. Moreover, the determination of geometric
joint parameters is reliant upon macrographs to assess the influence of the joining
time on the geometric joint formation. The test results show that a significant
increase in joining speed with a resulting reduction in process time is feasible.
Although the joining properties are affected, reliable joining is possible. In
particular, the shaft thickness of the rivet is influenced by the varying proportion
of the tumbling process in the joining operation and increases with higher joining
speeds.
author:
- first_name: Simon
full_name: Wituschek, Simon
last_name: Wituschek
- first_name: Leonie
full_name: Elbel, Leonie
last_name: Elbel
- first_name: Michael
full_name: Lechner, Michael
last_name: Lechner
citation:
ama: 'Wituschek S, Elbel L, Lechner M. Influence of the process time on a self-piercing
riveting process with tumbling kinematic. Proceedings of the Institution of
Mechanical Engineers, Part E: Journal of Process Mechanical Engineering. Published
online 2024. doi:10.1177/09544089241248430'
apa: 'Wituschek, S., Elbel, L., & Lechner, M. (2024). Influence of the process
time on a self-piercing riveting process with tumbling kinematic. Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering. https://doi.org/10.1177/09544089241248430'
bibtex: '@article{Wituschek_Elbel_Lechner_2024, title={Influence of the process
time on a self-piercing riveting process with tumbling kinematic}, DOI={10.1177/09544089241248430},
journal={Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering}, publisher={SAGE Publications}, author={Wituschek,
Simon and Elbel, Leonie and Lechner, Michael}, year={2024} }'
chicago: 'Wituschek, Simon, Leonie Elbel, and Michael Lechner. “Influence of the
Process Time on a Self-Piercing Riveting Process with Tumbling Kinematic.” Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering, 2024. https://doi.org/10.1177/09544089241248430.'
ieee: 'S. Wituschek, L. Elbel, and M. Lechner, “Influence of the process time on
a self-piercing riveting process with tumbling kinematic,” Proceedings of the
Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering,
2024, doi: 10.1177/09544089241248430.'
mla: 'Wituschek, Simon, et al. “Influence of the Process Time on a Self-Piercing
Riveting Process with Tumbling Kinematic.” Proceedings of the Institution of
Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, SAGE
Publications, 2024, doi:10.1177/09544089241248430.'
short: 'S. Wituschek, L. Elbel, M. Lechner, Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering (2024).'
date_created: 2024-09-06T08:08:43Z
date_updated: 2024-09-06T08:10:48Z
doi: 10.1177/09544089241248430
language:
- iso: eng
publication: 'Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering'
publication_identifier:
issn:
- 0954-4089
- 2041-3009
publication_status: published
publisher: SAGE Publications
status: public
title: Influence of the process time on a self-piercing riveting process with tumbling
kinematic
type: journal_article
user_id: '83423'
year: '2024'
...
---
_id: '58192'
abstract:
- lang: eng
text: Increasing material costs, decreasing availability, and ever-higher
demands on environmental compatibility and complexity require new strategies in
the development and production of functional components. Consequently, a combined
approach from the areas of design, material science, and manufacturing is mandatory,
in order to meet the requirements. Reducing the number of parts, using lightweight
materials and applying hybrid components with a multimaterial mix are possible
solutions. Nevertheless, conventional joining operations like welding or riveting
are reaching their limits in terms of material utilization, load-bearing capacity
as well as versatility of the process. Thus, innovative and versatile joining
by forming operations and process combinations are focus of current research.
In this context, the innovative process of orbital forming had been investigated
as a joining by forming operation to manufacture load-adapted hybrid functional
components. By tilting of one tool component during the process, a radial material
flow is generated, allowing the crimping of the two joining partners. Nevertheless,
the load-bearing capacity in axial direction could be identified as limiting factor
for a possible application. Therefore, the aim of this investigation is the development
of a fundamental process understanding on the influence of a novel geometrical
adaption of the joint on the resulting load bearing capacity. The influence of
varying geometrical proportions of the joint on the quality is evaluated, considering
the form filling, the geometrical properties of the components as well as the
maximum transmittable axial load. As joining partners, the dual-phase steel DP600
and the aluminum alloy EN AW-5754 with a thickness of 2.0 mm are used.
author:
- first_name: A.
full_name: Hetzel, A.
last_name: Hetzel
- first_name: S.
full_name: Wituschek, S.
last_name: Wituschek
- first_name: D.
full_name: Römisch, D.
last_name: Römisch
- first_name: F.
full_name: Sippel, F.
last_name: Sippel
- first_name: M.
full_name: Lechner, M.
last_name: Lechner
- first_name: M.
full_name: Merklein, M.
last_name: Merklein
citation:
ama: 'Hetzel A, Wituschek S, Römisch D, Sippel F, Lechner M, Merklein M. Investigation
on the load-bearing capacity and joint formation of hybrid functional components
joined by orbital forming. Proceedings of the Institution of Mechanical Engineers,
Part E: Journal of Process Mechanical Engineering. Published online 2024.
doi:10.1177/09544089241282807'
apa: 'Hetzel, A., Wituschek, S., Römisch, D., Sippel, F., Lechner, M., & Merklein,
M. (2024). Investigation on the load-bearing capacity and joint formation of hybrid
functional components joined by orbital forming. Proceedings of the Institution
of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering.
https://doi.org/10.1177/09544089241282807'
bibtex: '@article{Hetzel_Wituschek_Römisch_Sippel_Lechner_Merklein_2024, title={Investigation
on the load-bearing capacity and joint formation of hybrid functional components
joined by orbital forming}, DOI={10.1177/09544089241282807},
journal={Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering}, publisher={SAGE Publications}, author={Hetzel,
A. and Wituschek, S. and Römisch, D. and Sippel, F. and Lechner, M. and Merklein,
M.}, year={2024} }'
chicago: 'Hetzel, A., S. Wituschek, D. Römisch, F. Sippel, M. Lechner, and M. Merklein.
“Investigation on the Load-Bearing Capacity and Joint Formation of Hybrid Functional
Components Joined by Orbital Forming.” Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering, 2024. https://doi.org/10.1177/09544089241282807.'
ieee: 'A. Hetzel, S. Wituschek, D. Römisch, F. Sippel, M. Lechner, and M. Merklein,
“Investigation on the load-bearing capacity and joint formation of hybrid functional
components joined by orbital forming,” Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering, 2024, doi: 10.1177/09544089241282807.'
mla: 'Hetzel, A., et al. “Investigation on the Load-Bearing Capacity and Joint Formation
of Hybrid Functional Components Joined by Orbital Forming.” Proceedings of
the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering, SAGE Publications, 2024, doi:10.1177/09544089241282807.'
short: 'A. Hetzel, S. Wituschek, D. Römisch, F. Sippel, M. Lechner, M. Merklein,
Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process
Mechanical Engineering (2024).'
date_created: 2025-01-15T12:13:53Z
date_updated: 2025-01-15T12:15:04Z
doi: 10.1177/09544089241282807
language:
- iso: eng
publication: 'Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering'
publication_identifier:
issn:
- 0954-4089
- 2041-3009
publication_status: published
publisher: SAGE Publications
status: public
title: Investigation on the load-bearing capacity and joint formation of hybrid functional
components joined by orbital forming
type: journal_article
user_id: '83423'
year: '2024'
...
---
_id: '58348'
abstract:
- lang: eng
text: ' Clinching is a mechanical joining technology, in which a mainly
form-fit joint is created by means of local cold forming. To characterize the
load-bearing behavior of such joints, they are typically analyzed destructively,
for example by tensile-shear tests in combination with metallographic sections.
However, both the initiation and progress of failure can only be described to
a limited extent by this method. Furthermore, these tests allow only limited conclusions
about clinch points under in-service loading. More purposefully, clinch points
can be analyzed nondestructively by combining in-situ computed tomography (CT)
and transient dynamic analysis (TDA). The TDA continuously measures the dynamic
behavior of the specimen and indicates failure events like crack initiation, which
then can be evaluated thoroughly by stopping the test and performing a CT scan.
To qualify the TDA for this task, it is necessary to link the observed damage
behavior with specific dynamic characteristics. In this work, the complementation
of in-situ CT and TDA is investigated by testing a clinched single-lap tensile-shear
specimen made of aluminum. The testing procedure is stepwise: at certain displacement
levels, the specimen is investigated by in-situ CT and TDA. While the in-situ
CT provides the location, extent, and development of the failure phenomena, the
TDA uses this information to evaluate the dynamic signal and detect relevant frequency
ranges, which indicate damage events. The results demonstrate, that failure initiation
and progression can be analyzed efficiently by combining both measuring systems.
The TDA reliably detects relevant signal changes in the monitored frequency band.
By means of in-situ computed tomography, the corresponding failure phenomena can
be described in detail, enhancing the understanding of the load-bearing and deformation
behavior of clinch points. The concatenation of characteristic signal changes
and observed failure phenomena can henceforth be transferred to analyze complex
structures during operation nondestructively by TDA. '
article_type: original
author:
- first_name: Gregor
full_name: Reschke, Gregor
last_name: Reschke
- first_name: Daniel
full_name: Köhler, Daniel
last_name: Köhler
- first_name: Robert
full_name: Kupfer, Robert
last_name: Kupfer
- first_name: Juliane
full_name: Troschitz, Juliane
last_name: Troschitz
- first_name: Maik
full_name: Gude, Maik
last_name: Gude
- first_name: Alexander
full_name: Brosius, Alexander
last_name: Brosius
citation:
ama: 'Reschke G, Köhler D, Kupfer R, Troschitz J, Gude M, Brosius A. In-situ computed
tomography and transient dynamic analysis – failure analysis of a single-lap tensile-shear
test with clinch points. Proceedings of the Institution of Mechanical Engineers,
Part E: Journal of Process Mechanical Engineering. Published online 2024.
doi:10.1177/09544089241251646'
apa: 'Reschke, G., Köhler, D., Kupfer, R., Troschitz, J., Gude, M., & Brosius,
A. (2024). In-situ computed tomography and transient dynamic analysis – failure
analysis of a single-lap tensile-shear test with clinch points. Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering. https://doi.org/10.1177/09544089241251646'
bibtex: '@article{Reschke_Köhler_Kupfer_Troschitz_Gude_Brosius_2024, title={In-situ
computed tomography and transient dynamic analysis – failure analysis of a single-lap
tensile-shear test with clinch points}, DOI={10.1177/09544089241251646},
journal={Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering}, publisher={SAGE Publications}, author={Reschke,
Gregor and Köhler, Daniel and Kupfer, Robert and Troschitz, Juliane and Gude,
Maik and Brosius, Alexander}, year={2024} }'
chicago: 'Reschke, Gregor, Daniel Köhler, Robert Kupfer, Juliane Troschitz, Maik
Gude, and Alexander Brosius. “In-Situ Computed Tomography and Transient Dynamic
Analysis – Failure Analysis of a Single-Lap Tensile-Shear Test with Clinch Points.”
Proceedings of the Institution of Mechanical Engineers, Part E: Journal of
Process Mechanical Engineering, 2024. https://doi.org/10.1177/09544089241251646.'
ieee: 'G. Reschke, D. Köhler, R. Kupfer, J. Troschitz, M. Gude, and A. Brosius,
“In-situ computed tomography and transient dynamic analysis – failure analysis
of a single-lap tensile-shear test with clinch points,” Proceedings of the
Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering,
2024, doi: 10.1177/09544089241251646.'
mla: 'Reschke, Gregor, et al. “In-Situ Computed Tomography and Transient Dynamic
Analysis – Failure Analysis of a Single-Lap Tensile-Shear Test with Clinch Points.”
Proceedings of the Institution of Mechanical Engineers, Part E: Journal of
Process Mechanical Engineering, SAGE Publications, 2024, doi:10.1177/09544089241251646.'
short: 'G. Reschke, D. Köhler, R. Kupfer, J. Troschitz, M. Gude, A. Brosius, Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering (2024).'
date_created: 2025-01-23T19:21:45Z
date_updated: 2025-01-23T19:32:03Z
department:
- _id: '43'
- _id: '157'
doi: 10.1177/09544089241251646
keyword:
- Clinching
- Non-destructive testing
- Transient Dynamic Analysis
language:
- iso: eng
main_file_link:
- open_access: '1'
oa: '1'
project:
- _id: '133'
name: 'TRR 285 - C: TRR 285 - Project Area C'
- _id: '148'
name: 'TRR 285 – C04: TRR 285 - Subproject C04'
publication: 'Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering'
publication_identifier:
issn:
- 0954-4089
- 2041-3009
publication_status: published
publisher: SAGE Publications
quality_controlled: '1'
status: public
title: In-situ computed tomography and transient dynamic analysis – failure analysis
of a single-lap tensile-shear test with clinch points
type: journal_article
user_id: '98812'
year: '2024'
...
---
_id: '60106'
abstract:
- lang: eng
text: ' Clinching is a mechanical joining technology, in which a mainly
form-fit joint is created by means of local cold forming. To characterize the
load-bearing behavior of such joints, they are typically analyzed destructively,
for example by tensile-shear tests in combination with metallographic sections.
However, both the initiation and progress of failure can only be described to
a limited extent by this method. Furthermore, these tests allow only limited conclusions
about clinch points under in-service loading. More purposefully, clinch points
can be analyzed nondestructively by combining in-situ computed tomography (CT)
and transient dynamic analysis (TDA). The TDA continuously measures the dynamic
behavior of the specimen and indicates failure events like crack initiation, which
then can be evaluated thoroughly by stopping the test and performing a CT scan.
To qualify the TDA for this task, it is necessary to link the observed damage
behavior with specific dynamic characteristics. In this work, the complementation
of in-situ CT and TDA is investigated by testing a clinched single-lap tensile-shear
specimen made of aluminum. The testing procedure is stepwise: at certain displacement
levels, the specimen is investigated by in-situ CT and TDA. While the in-situ
CT provides the location, extent, and development of the failure phenomena, the
TDA uses this information to evaluate the dynamic signal and detect relevant frequency
ranges, which indicate damage events. The results demonstrate, that failure initiation
and progression can be analyzed efficiently by combining both measuring systems.
The TDA reliably detects relevant signal changes in the monitored frequency band.
By means of in-situ computed tomography, the corresponding failure phenomena can
be described in detail, enhancing the understanding of the load-bearing and deformation
behavior of clinch points. The concatenation of characteristic signal changes
and observed failure phenomena can henceforth be transferred to analyze complex
structures during operation nondestructively by TDA. '
author:
- first_name: G
full_name: Reschke, G
last_name: Reschke
- first_name: D
full_name: Köhler, D
last_name: Köhler
- first_name: R
full_name: Kupfer, R
last_name: Kupfer
- first_name: J
full_name: Troschitz, J
last_name: Troschitz
- first_name: M
full_name: Gude, M
last_name: Gude
- first_name: A
full_name: Brosius, A
last_name: Brosius
citation:
ama: 'Reschke G, Köhler D, Kupfer R, Troschitz J, Gude M, Brosius A. In-situ computed
tomography and transient dynamic analysis – failure analysis of a single-lap tensile-shear
test with clinch points. Proceedings of the Institution of Mechanical Engineers,
Part E: Journal of Process Mechanical Engineering. Published online 2024.
doi:10.1177/09544089241251646'
apa: 'Reschke, G., Köhler, D., Kupfer, R., Troschitz, J., Gude, M., & Brosius,
A. (2024). In-situ computed tomography and transient dynamic analysis – failure
analysis of a single-lap tensile-shear test with clinch points. Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering. https://doi.org/10.1177/09544089241251646'
bibtex: '@article{Reschke_Köhler_Kupfer_Troschitz_Gude_Brosius_2024, title={In-situ
computed tomography and transient dynamic analysis – failure analysis of a single-lap
tensile-shear test with clinch points}, DOI={10.1177/09544089241251646},
journal={Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering}, publisher={SAGE Publications}, author={Reschke,
G and Köhler, D and Kupfer, R and Troschitz, J and Gude, M and Brosius, A}, year={2024}
}'
chicago: 'Reschke, G, D Köhler, R Kupfer, J Troschitz, M Gude, and A Brosius. “In-Situ
Computed Tomography and Transient Dynamic Analysis – Failure Analysis of a Single-Lap
Tensile-Shear Test with Clinch Points.” Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering, 2024. https://doi.org/10.1177/09544089241251646.'
ieee: 'G. Reschke, D. Köhler, R. Kupfer, J. Troschitz, M. Gude, and A. Brosius,
“In-situ computed tomography and transient dynamic analysis – failure analysis
of a single-lap tensile-shear test with clinch points,” Proceedings of the
Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering,
2024, doi: 10.1177/09544089241251646.'
mla: 'Reschke, G., et al. “In-Situ Computed Tomography and Transient Dynamic Analysis
– Failure Analysis of a Single-Lap Tensile-Shear Test with Clinch Points.” Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering, SAGE Publications, 2024, doi:10.1177/09544089241251646.'
short: 'G. Reschke, D. Köhler, R. Kupfer, J. Troschitz, M. Gude, A. Brosius, Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering (2024).'
date_created: 2025-06-02T20:03:39Z
date_updated: 2025-06-02T20:18:31Z
department:
- _id: '157'
- _id: '43'
doi: 10.1177/09544089241251646
language:
- iso: eng
project:
- _id: '130'
grant_number: '418701707'
name: 'TRR 285: TRR 285: Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen
Prozessketten'
- _id: '133'
name: 'TRR 285 - C: TRR 285 - Project Area C'
- _id: '148'
name: 'TRR 285 – C04: TRR 285 - Subproject C04'
publication: 'Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering'
publication_identifier:
issn:
- 0954-4089
- 2041-3009
publication_status: published
publisher: SAGE Publications
status: public
title: In-situ computed tomography and transient dynamic analysis – failure analysis
of a single-lap tensile-shear test with clinch points
type: journal_article
user_id: '83408'
year: '2024'
...
---
_id: '61413'
abstract:
- lang: eng
text: Climate change has led to a large number of countries deciding to reduce carbon
dioxide (CO2) emissions significantly. As the mobility sector
is a major contributor to CO2, various strategies are being
pursued to achieve the climate targets set. An increasingly applied lightweight
design method is the use of multi-material constructions. To join these structures,
mechanical joining technologies such as self-pierce riveting are being used. As
a result of the currently rigid tool systems, which cannot react to changing boundary
conditions, a large number of rivet–die combinations is required to join the rising
number of materials as well as material thickness combinations. Thus, new, versatile
joining technologies are needed that can react to the described changes. The versatile
self-piercing riveting (V-SPR) process is one possible approach. In this process,
different material thicknesses can be joined by using a multi-range capable rivet
which is set by a joining system with extended actuator technology. In this study,
the V-SPR joining process is analysed numerically according to the influence of
the geometrical rivet parameters on the joints characteristics as well as the
resulting material flow. The investigations showed that the shank geometry has
a decisive influence on the expansion of the rivet. Furthermore, the rivet length
could be proven to be an influencing factor. By changing the head radii and the
protrusion height, the forming behaviour of the rivet head onto the punch-sided
joining part could be improved and thus the formation of air pockets was prevented.
Based on the numerical investigations, a novel rivet geometry was developed and
produced by machining. Subsequently, experimentally produced joints were analysed
according to their joint formation and load-bearing capacity.
article_number: '09544089241263141'
author:
- first_name: Fabian
full_name: Kappe, Fabian
id: '66459'
last_name: Kappe
- first_name: Mathias
full_name: Bobbert, Mathias
id: '7850'
last_name: Bobbert
- first_name: Gerson
full_name: Meschut, Gerson
id: '32056'
last_name: Meschut
orcid: 0000-0002-2763-1246
citation:
ama: 'Kappe F, Bobbert M, Meschut G. Investigation of the influence of the rivet
geometry on joint formation for a versatile self-piercing riveting process. Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering. Published online 2024. doi:10.1177/09544089241263141'
apa: 'Kappe, F., Bobbert, M., & Meschut, G. (2024). Investigation of the influence
of the rivet geometry on joint formation for a versatile self-piercing riveting
process. Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering, Article 09544089241263141. https://doi.org/10.1177/09544089241263141'
bibtex: '@article{Kappe_Bobbert_Meschut_2024, title={Investigation of the influence
of the rivet geometry on joint formation for a versatile self-piercing riveting
process}, DOI={10.1177/09544089241263141},
number={09544089241263141}, journal={Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering}, publisher={SAGE
Publications}, author={Kappe, Fabian and Bobbert, Mathias and Meschut, Gerson},
year={2024} }'
chicago: 'Kappe, Fabian, Mathias Bobbert, and Gerson Meschut. “Investigation of
the Influence of the Rivet Geometry on Joint Formation for a Versatile Self-Piercing
Riveting Process.” Proceedings of the Institution of Mechanical Engineers,
Part E: Journal of Process Mechanical Engineering, 2024. https://doi.org/10.1177/09544089241263141.'
ieee: 'F. Kappe, M. Bobbert, and G. Meschut, “Investigation of the influence of
the rivet geometry on joint formation for a versatile self-piercing riveting process,”
Proceedings of the Institution of Mechanical Engineers, Part E: Journal of
Process Mechanical Engineering, Art. no. 09544089241263141, 2024, doi: 10.1177/09544089241263141.'
mla: 'Kappe, Fabian, et al. “Investigation of the Influence of the Rivet Geometry
on Joint Formation for a Versatile Self-Piercing Riveting Process.” Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering, 09544089241263141, SAGE Publications, 2024, doi:10.1177/09544089241263141.'
short: 'F. Kappe, M. Bobbert, G. Meschut, Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering (2024).'
date_created: 2025-09-23T13:06:35Z
date_updated: 2025-09-23T13:15:51Z
department:
- _id: '43'
- _id: '157'
doi: 10.1177/09544089241263141
language:
- iso: eng
project:
- _id: '130'
name: 'TRR 285: Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen
Prozessketten'
- _id: '133'
name: TRR 285 - Project Area C
- _id: '146'
name: TRR 285 - Subproject C02
publication: 'Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering'
publication_identifier:
issn:
- 0954-4089
- 2041-3009
publication_status: published
publisher: SAGE Publications
quality_controlled: '1'
status: public
title: Investigation of the influence of the rivet geometry on joint formation for
a versatile self-piercing riveting process
type: journal_article
user_id: '44935'
year: '2024'
...
---
_id: '61414'
abstract:
- lang: eng
text: The increasing significance of ecological responsibility, stricter political
regulations and economic objectives are driving innovation in research fields
such as lightweight construction. One of the most important popular methods is
the use of multi-material systems. Due to the different geometric and mechanical
properties of the various materials used, resource efficient applications and
utilizations are possible. Great challenges arise for the joining processes to
realize these multi-material systems, since conventional joining processes reach
their limits. In the field of mechanical joining processes, there are continuously
new approaches, such as superimposing the punch in a self-piercing riveting process
with a tumbling kinematic, to increase the number of adaptable process parameters
and enhance the process control. Through various preliminary tests, a good understanding
of the process has been developed, which allows to directly control the geometric
joint parameters by configuring the tumbling strategy. A major challenge, particularly
with regard to future industrial applications, is the process time, which is comparatively
high due to the tumbling kinematics. In the investigations, a reduction of approximately
90% of the process time is targeted by adapting the joining and tumbling strategy.
Therefore, the correlation of the traverse velocity and the tumbling velocity
are examined in a gradual series of experiments. To represent realistic applications,
the experiments are carried out with a dual-phase steel and a precipitation-hardening
aluminum alloy. For identifying the influence of the process parameters on the
joining process, a constant rivet–die combination is applied. Further, the examination
of force–displacement curves is conducted. Moreover, the determination of geometric
joint parameters is reliant upon macrographs to assess the influence of the joining
time on the geometric joint formation. The test results show that a significant
increase in joining speed with a resulting reduction in process time is feasible.
Although the joining properties are affected, reliable joining is possible. In
particular, the shaft thickness of the rivet is influenced by the varying proportion
of the tumbling process in the joining operation and increases with higher joining
speeds.
article_number: '09544089241248430'
author:
- first_name: Simon
full_name: Wituschek, Simon
id: '83423'
last_name: Wituschek
- first_name: Leonie
full_name: Elbel, Leonie
last_name: Elbel
- first_name: Michael
full_name: Lechner, Michael
last_name: Lechner
citation:
ama: 'Wituschek S, Elbel L, Lechner M. Influence of the process time on a self-piercing
riveting process with tumbling kinematic. Proceedings of the Institution of
Mechanical Engineers, Part E: Journal of Process Mechanical Engineering. Published
online 2024. doi:10.1177/09544089241248430'
apa: 'Wituschek, S., Elbel, L., & Lechner, M. (2024). Influence of the process
time on a self-piercing riveting process with tumbling kinematic. Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering, Article 09544089241248430. https://doi.org/10.1177/09544089241248430'
bibtex: '@article{Wituschek_Elbel_Lechner_2024, title={Influence of the process
time on a self-piercing riveting process with tumbling kinematic}, DOI={10.1177/09544089241248430},
number={09544089241248430}, journal={Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering}, publisher={SAGE
Publications}, author={Wituschek, Simon and Elbel, Leonie and Lechner, Michael},
year={2024} }'
chicago: 'Wituschek, Simon, Leonie Elbel, and Michael Lechner. “Influence of the
Process Time on a Self-Piercing Riveting Process with Tumbling Kinematic.” Proceedings
of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering, 2024. https://doi.org/10.1177/09544089241248430.'
ieee: 'S. Wituschek, L. Elbel, and M. Lechner, “Influence of the process time on
a self-piercing riveting process with tumbling kinematic,” Proceedings of the
Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering,
Art. no. 09544089241248430, 2024, doi: 10.1177/09544089241248430.'
mla: 'Wituschek, Simon, et al. “Influence of the Process Time on a Self-Piercing
Riveting Process with Tumbling Kinematic.” Proceedings of the Institution of
Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 09544089241248430,
SAGE Publications, 2024, doi:10.1177/09544089241248430.'
short: 'S. Wituschek, L. Elbel, M. Lechner, Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering (2024).'
date_created: 2025-09-23T13:16:12Z
date_updated: 2025-09-23T13:33:49Z
doi: 10.1177/09544089241248430
language:
- iso: eng
project:
- _id: '130'
name: 'TRR 285: Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen
Prozessketten'
- _id: '133'
name: TRR 285 - Project Area C
- _id: '146'
name: TRR 285 - Subproject C02
publication: 'Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering'
publication_identifier:
issn:
- 0954-4089
- 2041-3009
publication_status: published
publisher: SAGE Publications
quality_controlled: '1'
status: public
title: Influence of the process time on a self-piercing riveting process with tumbling
kinematic
type: journal_article
user_id: '44935'
year: '2024'
...
---
_id: '61415'
abstract:
- lang: eng
text: 'Increasing material costs, decreasing availability, and ever-higher demands
on environmental compatibility and complexity require new strategies in the development
and production of functional components. Consequently, a combined approach from
the areas of design, material science, and manufacturing is mandatory, in order
to meet the requirements. Reducing the number of parts, using lightweight materials
and applying hybrid components with a multimaterial mix are possible solutions.
Nevertheless, conventional joining operations like welding or riveting are reaching
their limits in terms of material utilization, load-bearing capacity as well as
versatility of the process. Thus, innovative and versatile joining by forming
operations and process combinations are focus of current research. In this context,
the innovative process of orbital forming had been investigated as a joining by
forming operation to manufacture load-adapted hybrid functional components. By
tilting of one tool component during the process, a radial material flow is generated,
allowing the crimping of the two joining partners. Nevertheless, the load-bearing
capacity in axial direction could be identified as limiting factor for a possible
application. Therefore, the aim of this investigation is the development of a
fundamental process understanding on the influence of a novel geometrical adaption
of the joint on the resulting load bearing capacity. The influence of varying
geometrical proportions of the joint on the quality is evaluated, considering
the form filling, the geometrical properties of the components as well as the
maximum transmittable axial load. As joining partners, the dual-phase steel DP600
and the aluminum alloy EN AW-5754 with a thickness of 2.0 mm are used. '
article_number: '09544089241282807'
author:
- first_name: A.
full_name: Hetzel, A.
last_name: Hetzel
- first_name: Simon
full_name: Wituschek, Simon
id: '83423'
last_name: Wituschek
- first_name: D.
full_name: Römisch, D.
last_name: Römisch
- first_name: F.
full_name: Sippel, F.
last_name: Sippel
- first_name: M.
full_name: Lechner, M.
last_name: Lechner
- first_name: M.
full_name: Merklein, M.
last_name: Merklein
citation:
ama: 'Hetzel A, Wituschek S, Römisch D, Sippel F, Lechner M, Merklein M. Investigation
on the load-bearing capacity and joint formation of hybrid functional components
joined by orbital forming. Proceedings of the Institution of Mechanical Engineers,
Part E: Journal of Process Mechanical Engineering. Published online 2024.
doi:10.1177/09544089241282807'
apa: 'Hetzel, A., Wituschek, S., Römisch, D., Sippel, F., Lechner, M., & Merklein,
M. (2024). Investigation on the load-bearing capacity and joint formation of hybrid
functional components joined by orbital forming. Proceedings of the Institution
of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering,
Article 09544089241282807. https://doi.org/10.1177/09544089241282807'
bibtex: '@article{Hetzel_Wituschek_Römisch_Sippel_Lechner_Merklein_2024, title={Investigation
on the load-bearing capacity and joint formation of hybrid functional components
joined by orbital forming}, DOI={10.1177/09544089241282807},
number={09544089241282807}, journal={Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering}, publisher={SAGE
Publications}, author={Hetzel, A. and Wituschek, Simon and Römisch, D. and Sippel,
F. and Lechner, M. and Merklein, M.}, year={2024} }'
chicago: 'Hetzel, A., Simon Wituschek, D. Römisch, F. Sippel, M. Lechner, and M.
Merklein. “Investigation on the Load-Bearing Capacity and Joint Formation of Hybrid
Functional Components Joined by Orbital Forming.” Proceedings of the Institution
of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering,
2024. https://doi.org/10.1177/09544089241282807.'
ieee: 'A. Hetzel, S. Wituschek, D. Römisch, F. Sippel, M. Lechner, and M. Merklein,
“Investigation on the load-bearing capacity and joint formation of hybrid functional
components joined by orbital forming,” Proceedings of the Institution of Mechanical
Engineers, Part E: Journal of Process Mechanical Engineering, Art. no. 09544089241282807,
2024, doi: 10.1177/09544089241282807.'
mla: 'Hetzel, A., et al. “Investigation on the Load-Bearing Capacity and Joint Formation
of Hybrid Functional Components Joined by Orbital Forming.” Proceedings of
the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical
Engineering, 09544089241282807, SAGE Publications, 2024, doi:10.1177/09544089241282807.'
short: 'A. Hetzel, S. Wituschek, D. Römisch, F. Sippel, M. Lechner, M. Merklein,
Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process
Mechanical Engineering (2024).'
date_created: 2025-09-23T13:21:21Z
date_updated: 2025-09-23T13:34:05Z
doi: 10.1177/09544089241282807
language:
- iso: eng
project:
- _id: '130'
name: 'TRR 285: Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen
Prozessketten'
- _id: '133'
name: TRR 285 - Project Area C
- _id: '146'
name: TRR 285 - Subproject C02
- _id: '145'
name: TRR 285 - Subproject C01
publication: 'Proceedings of the Institution of Mechanical Engineers, Part E: Journal
of Process Mechanical Engineering'
publication_identifier:
issn:
- 0954-4089
- 2041-3009
publication_status: published
publisher: SAGE Publications
quality_controlled: '1'
status: public
title: Investigation on the load-bearing capacity and joint formation of hybrid functional
components joined by orbital forming
type: journal_article
user_id: '44935'
year: '2024'
...