@article{48075, abstract = {{AbstractThe constantly increasing challenges of production technology for the economic and resource-saving production of metallic workpieces require, among other things, the optimisation of existing processes. Forming technology, which is confronted with new challenges regarding the quality of the workpieces, must also organise the individual processes more efficiently and at the same time more reliably in order to be able to guarantee good workpiece quality and at the same time to be able to produce economically. One way to meet these challenges is to carry out the forming processes in closed-loop control systems using softsensors. Despite the many potential applications of softsensors in the field of forming technology, there is still no definition of the term softsensor. This publication therefore proposes a definition of the softsensor based on the definition of a sensor and the distinction from the observer, which on the one hand is intended to stimulate scientific discourse and on the other hand is also intended to form the basis for further scientific work. Based on this definition, a wide variety of highly topical application examples of various softsensors in the field of forming technology are given.}}, author = {{Homberg, Werner and Arian, Bahman and Arne, Viktor and Borgert, Thomas and Brosius, Alexander and Groche, Peter and Hartmann, Christoph and Kersting, Lukas and Laue, Robert and Martschin, Juri and Meurer, Thomas and Spies, Daniel and Tekkaya, A. Erman and Trächtler, Ansgar and Volk, Wolfram and Wendler, Frank and Wrobel, Malte}}, issn = {{0944-6524}}, journal = {{Production Engineering}}, keywords = {{Industrial and Manufacturing Engineering, Mechanical Engineering}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Softsensors: key component of property control in forming technology}}}, doi = {{10.1007/s11740-023-01227-1}}, year = {{2023}}, } @article{34213, abstract = {{In this paper, a study based on experimental and numerical simulations is performed to analyze fatigue cracks in clinched joints. An experimental investigation is conducted to determine the failure modes of clinched joints under cyclic loading at different load amplitudes with single-lap shear tests. In addition, numerical FEM simulations of clinching process and subsequent shear loading are performed to support the experimental investigations by analyzing the state of stresses at the location of failure. An attempt is made to explain the location of crack initiation in the experiments using evaluation variables such as contact shear stress and maximum principal stress.}}, author = {{Ewenz, L. and Bielak, Christian Roman and Otroshi, Mortaza and Bobbert, Mathias and Meschut, Gerson and Zimmermann, M.}}, issn = {{0944-6524}}, journal = {{Production Engineering}}, keywords = {{Industrial and Manufacturing Engineering, Mechanical Engineering}}, number = {{2-3}}, pages = {{305--313}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Numerical and experimental identification of fatigue crack initiation sites in clinched joints}}}, doi = {{10.1007/s11740-022-01124-z}}, volume = {{16}}, year = {{2022}}, } @article{43156, abstract = {{The use of mechanical joining technologies offers the possibility of joining mixed material structures, which are used in particular in lightweight construction. An integrated securing of the joinability in versatile process chains is currently hardly possible as the number of combinable tool variants as well as variable force- and path-based process parameters is infinite. A versatile process chain, i.e. a sequence of all the processes and process steps required for product manufacturing, enables targeted changes to the semi-finished product, the joint, the component or the joining process that exceed the originally planned extend while still ensuring joinability. In detail, it leads to a unique joint with its own mechanical property profile, which, against the background of the resulting infinite number of combinations, makes it impossible to secure the joinability on the conventional experimentally based approach without extensive safety factors. The Transregional Colaborative Research Center 285 (TCRC285), which also initiated this special issue, is intended to enable mechanical joining technology to be versatile in the sense of high application flexibility. This is to be achieved with a numerical representation of the complete process chain from the incoming semi finished product via the joining part production and the joining process to the property profile of the joint in the operating phase. Thus a predictability of the joinability can be achieved and improvements in the individual life cycles of a joint can be realized by grasping the cause-and-effect relationships. On the basis of this knowledge, new possibilities for intervention in the joining process are to be created for the adaptation of the joining processes. With the aid of the methods developed for this purpose, tools will later be available to the end user to substitute the large number of mechanical joining processes or joining task-specific configurations with a smaller number of adaptable processes. This expands the flexibility in material choices, enabling challenges in environmental issues and sustainability to be overcome.}}, author = {{Meschut, Gerson and Merklein, Marion and Brosius, Alexander and Bobbert, Mathias}}, issn = {{0944-6524}}, journal = {{Production Engineering}}, keywords = {{Industrial and Manufacturing Engineering, Mechanical Engineering}}, number = {{2-3}}, pages = {{187--191}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Mechanical joining in versatile process chains}}}, doi = {{10.1007/s11740-022-01125-y}}, volume = {{16}}, year = {{2022}}, } @article{34241, abstract = {{Due to the increasing use of multi-material constructions and the resulting material incompatibilities, mechanical joining technologies are gaining in importance. The reasons for this are the variety of joining possibilities as well as high load-bearing capacities. However, the currently rigid tooling systems cannot react to changing boundary conditions, such as changed sheet thicknesses or strength. For this reason, a large number of specialised joining processes have been developed to expand the range of applications. Using a versatile self-piercing riveting process, multi-material structures are joined in this paper. In this process, a modified tool actuator technology is combined with multi-range capable auxiliary joining parts. The multi-range capability of the rivets is achieved by forming the rivet head onto the respective thickness of the joining part combination without creating a tooling set-up effort. The joints are investigated both experimentally on the basis of joint formation and load-bearing capacity tests as well as by means of numerical simulation. It turned out that all the joints examined could be manufactured according to the defined standards. The load-bearing capacities of the joints are comparable to those of conventionally joined joints. In some cases the joint fails prematurely, which is why lower energy absorptions are obtained. However, the maximum forces achieved are higher than those of conventional joints. Especially in the case of high-strength materials arranged on the die side, the interlock formation is low. In addition, the use of die-sided sheets requires a large deformation of the rivet head protrusion, which leads to an increase in stress and, as a result, to damage if the rivet head. However, a negative influence on the joint load-bearing capacity could be excluded.}}, author = {{Kappe, Fabian and Wituschek, Simon and Bobbert, Mathias and Lechner, Michael and Meschut, Gerson}}, issn = {{0944-6524}}, journal = {{Production Engineering}}, keywords = {{Industrial and Manufacturing Engineering, Mechanical Engineering}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Joining of multi-material structures using a versatile self-piercing riveting process}}}, doi = {{10.1007/s11740-022-01151-w}}, year = {{2022}}, } @article{30100, abstract = {{Since the application of mechanical joining methods, such as clinching or riveting, offers a robust solution for the generation of advanced multi-material connections, the use in the field of lightweight designs (e.g. automotive industry) is steadily increasing. Therefore, not only the design of an individual joint is required but also the dimensioning of the entire joining connection is crucial. However, in comparison to thermal joining techniques, such as spot welding, the evaluation of the joints’ resistance against defined requirements (e.g. types of load, minimal amount of load cycles) mainly relies on the consideration of expert knowledge, a few design principles and a small amount of experimental data. Since this generally implies the involvement of several domains, such as the material characterization or the part design, a tremendous amount of data and knowledge is separately generated for a certain dimensioning process. Nevertheless, the lack of formalization and standardization in representing the gained knowledge leads to a difficult and inconsistent reuse, sharing or searching of already existing information. Thus, this contribution presents a specific ontology for the provision of cross-domain knowledge about mechanical joining processes and highlights two potential use cases of this ontology in the design of clinched and pin joints.}}, author = {{Zirngibl, Christoph and Kügler, Patricia and Popp, Julian and Bielak, Christian Roman and Bobbert, Mathias and Drummer, Dietmar and Meschut, Gerson and Wartzack, Sandro and Schleich, Benjamin}}, issn = {{0944-6524}}, journal = {{Production Engineering}}, keywords = {{Industrial and Manufacturing Engineering, Mechanical Engineering}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Provision of cross-domain knowledge in mechanical joining using ontologies}}}, doi = {{10.1007/s11740-022-01117-y}}, year = {{2022}}, } @article{30963, abstract = {{AbstractIn this paper, a study based on experimental and numerical simulations is performed to analyze fatigue cracks in clinched joints. An experimental investigation is conducted to determine the failure modes of clinched joints under cyclic loading at different load amplitudes with single-lap shear tests. In addition, numerical FEM simulations of clinching process and subsequent shear loading are performed to support the experimental investigations by analyzing the state of stresses at the location of failure. An attempt is made to explain the location of crack initiation in the experiments using evaluation variables such as contact shear stress and maximum principal stress.}}, author = {{Ewenz, Lars and Bielak, Christian Roman and Otroshi, Mortaza and Bobbert, Mathias and Meschut, Gerson and Zimmermann, Martina}}, issn = {{0944-6524}}, journal = {{Production Engineering}}, keywords = {{Industrial and Manufacturing Engineering, Mechanical Engineering}}, number = {{2-3}}, pages = {{305--313}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Numerical and experimental identification of fatigue crack initiation sites in clinched joints}}}, doi = {{10.1007/s11740-022-01124-z}}, volume = {{16}}, year = {{2022}}, } @article{29951, abstract = {{The components of a body in white consist of many individual thin-walled sheet metal parts, which usually are manufactured in deep-drawing processes. In general, the conditions in a deep-drawing process change due to changing tribology conditions, varying degrees of spring back, or scattering material properties in the sheet blanks, which affects the resulting pre-strain. Mechanical joining processes, especially clinching, are influenced by these process-related pre-strains. The final geometric shape of a clinched joint is affected to a significant level by the prior material deformation when joining with constant process parameters. That leads to a change in the stiffness and force transmission in the clinched joint due to the different geometric dimensions, such as interlock, neck thickness and bottom thickness, which directly affect the load bearing capacity. Here, the influence of the pre-straining in the deep drawing process on the force distribution in clinch points in an automotive assembly is investigated by finite-element models numerically. In further studies, the results are implemented in an optimization tool for designing clinched components. The methodology starts with a pre-straining of metal sheets. This step is followed by 2D rotationally symmetric forming simulations of the joining process. The resulting mesh of each forming simulation is rotated and 3D models are obtained. The clinched joint solid model with pre-strains is used further to determine the joint stiffnesses. With the simulation of the same test set-up with an equivalent point-connector model, the equivalent stiffness for each pre-strain combination is determined. Simulations are performed on a clinched component to assess the influence of pre-strain and sheet thinning on the clinched joint loadings by using the equivalent stiffnesses. The investigations clearly show that for the selected component, the loadings at the clinch points are dependent on the sheet thinning and the stiffnesses due to pre-strain. The magnitude of the influence varies depending on the quantity considered. For example, the shear force is more sensitive to the joint stiffness than to the sheet thinning.}}, author = {{Martin, Sven and Bielak, Christian Roman and Bobbert, Mathias and Tröster, Thomas and Meschut, Gerson}}, issn = {{0944-6524}}, journal = {{Production Engineering}}, keywords = {{Industrial and Manufacturing Engineering, Mechanical Engineering}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Numerical investigation of the clinched joint loadings considering the initial pre-strain in the joining area}}}, doi = {{10.1007/s11740-021-01103-w}}, 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}}, } @article{28568, abstract = {{AbstractRecent developments in automotive and aircraft industry towards a multi-material design pose challenges for modern joining technologies due to different mechanical properties and material compositions of various materials such as composites and metals. Therefore, mechanical joining technologies like clinching are in the focus of current research activities. For multi-material joints of metals and thermoplastic composites thermally assisted clinching processes with advanced tool concepts are well developed. The material-specific properties of fibre-reinforced thermoplastics have a significant influence on the joining process and the resulting material structure in the joining zone. For this reason, it is important to investigate these influences in detail and to understand the phenomena occurring during the joining process. Additionally, this provides the basis for a validation of a numerical simulation of such joining processes. In this paper, the material structure in a joint resulting from a thermally assisted clinching process is investigated. The joining partners are an aluminium sheet and a thermoplastic composite (organo sheet). Using computed tomography enables a three-dimensional investigation that allows a detailed analysis of the phenomena in different joining stages and in the material structure of the finished joint. Consequently, this study provides a more detailed understanding of the material behavior of thermoplastic composites during thermally assisted clinching.}}, author = {{Gröger, Benjamin and Köhler, Daniel and Vorderbrüggen, Julian and Troschitz, Juliane and Kupfer, Robert and Meschut, Gerson and Gude, Maik}}, issn = {{0944-6524}}, journal = {{Production Engineering}}, title = {{{Computed tomography investigation of the material structure in clinch joints in aluminium fibre-reinforced thermoplastic sheets}}}, doi = {{10.1007/s11740-021-01091-x}}, year = {{2021}}, } @article{30674, abstract = {{AbstractIn addition to the classical strength calculation, it is important to design components with regard to fracture mechanics because defects and cracks in a component can drastically influence its strength or fatigue behavior. Cracks can propagate due to operational loads and consequently lead to component failure. The fracture mechanical analysis provides information on stable or unstable crack growth as well as about the direction and the growth rate of a crack. For this purpose, sufficient information has to be available about the crack location, the crack length, the component geometry, the component loading and the fracture mechanical material parameters. The fracture mechanical properties are determined experimentally with standardized specimens as defined by the guidelines of the American Society for Testing and Materials. In practice, however, especially in the context with damage cases or formed material fracture mechanical parameters directly for a component are of interest. However, standard specimens often cannot be extracted at all due to the complexity of the component geometry. Therefore, the development of special specimens is required whereby certain arrangements have to be made in advance. These arrangements are presented in the present paper in order to contribute to a holistic investigation chain for the experimental determination of fracture mechanical material parameters with special specimens.}}, author = {{Weiß, Deborah and Schramm, Britta and Kullmer, Gunter}}, issn = {{0944-6524}}, journal = {{Production Engineering}}, keywords = {{Industrial and Manufacturing Engineering, Mechanical Engineering}}, publisher = {{Springer Science and Business Media LLC}}, title = {{{Holistic investigation chain for the experimental determination of fracture mechanical material parameters with special specimens}}}, doi = {{10.1007/s11740-021-01096-6}}, year = {{2021}}, }