TY - CONF AB - 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. AU - Stephan, Richard AU - Brosius, Alexander ID - 36462 KW - clinching KW - mechanical joining KW - damping KW - model KW - evaluation KW - dynamics T2 - The 28th Saxon Conference on Forming Technology SFU and the 7th International Conference on Accuracy in Forming Technology ICAFT TI - Experimental Measurement Method and Evaluation of an Analytical Approach for Sound Conduction through Multiple Clinched Sheets ER - TY - CONF AB - The use of high-strength steel and aluminium is rising due to the intensified efforts being made in lightweight design, and self-piercing riveting is becoming increasingly important. Conventional rivets for self-piercing riveting differ in their geometry, the material used, the condition of the material and the coating. To shorten the manufacturing process, the use of stainless steel with high strain hardening as the rivet material represents a promising approach. This allows the coating of the rivets to be omitted due to the corrosion resistance of the material and, since the strength of the stainless steel is achieved by cold forming, heat treatment is no longer required. In addition, it is possible to adjust the local strength within the rivet. Because of that, the authors have elaborated a concept for using high nitrogen steel 1.3815 as the rivet material. The present investigation focusses on the joint strength in order to evaluate the capability of rivets in high nitrogen steel by comparison to conventional rivets made of treatable steel. Due to certain challenges in the forming process of the high nitrogen steel rivets, deviations result from the targeted rivet geometry. Mainly these deviations cause a lower joint strength with these rivets, which is, however, adequate. All in all, the capability of the new rivet is proven by the results of this investigation. AU - Uhe, Benedikt AU - Kuball, Clara-Maria AU - Merklein, Marion AU - Meschut, Gerson ID - 22274 KW - Self-piercing Riveting KW - Joining Technology KW - Rivet Geometry KW - Rivet Material KW - High Nitrogen Steel KW - Joint Strength TI - Strength of self-piercing riveted Joints with conventional Rivets and Rivets made of High Nitrogen Steel ER - TY - JOUR AB - The number of multi-material joints is increasing as a result of lightweight design. Self-piercing riveting (SPR) is an important mechanical joining technique for multi-material structures. Rivets for SPR are coated to prevent corrosion, but this coating also influences the friction that prevails during the joining process. The aim of the present investigation is to evaluate this influence. The investigation focuses on the common rivet coatings Almac® and zinc-nickel with topcoat as well as on uncoated rivet surfaces. First of all, the coating thickness and the uniformity of the coating distribution are analysed. Friction tests facilitate the classification of the surface properties. The influence of the friction on the characteristic joint parameters and the force-stroke curves is analysed by means of experimental joining tests. More in-depth knowledge of the effects that occur is achieved through the use of numerical simulation. Overall, it is shown that the surface condition of the rivet has an impact on the friction during the joining process and on the resulting joint. However, the detected deviations between different surface conditions do not restrict the operational capability of SPR and the properties of uncoated rivet surfaces, in particular, are similar to those of Almac®-coated rivets. It can thus be assumed that SPR with respect to the joining process is also possible without rivet coating in principle. AU - Uhe, Benedikt AU - Kuball, Clara-Maria AU - Merklein, Marion AU - Meschut, Gerson ID - 22272 JF - Key Engineering Materials KW - Coating KW - Friction KW - Joining TI - Influence of the Rivet Coating on the Friction during Self-Piercing Riveting VL - 883 ER - TY - GEN AB - The aim to reduce pollutant emission has led to a trend towards lightweight construction in car body development during the last years. As a consequence of the resulting need for multi-material design, mechanical joining technologies become increasingly important. Mechanical joining allows for the combination of dissimilar materials, while thermic joining techniques reach their limits. Self-piercing riveting enables the joining of dissimilar materials by using semi-tubular rivets as mechanical fasteners. The rivet production, however, is costly and time-consuming, as the rivets generally have to be hardened, tempered and coated after forming, in order to achieve an adequate strength and corrosion resistance. A promising approach to improve the efficiency of the rivet manufacturing is the use of high-strength high nitrogen steel as rivet material because these additional process steps would not be necessary anymore. As a result of the comparatively high nitrogen content, such steels have various beneficial properties like higher strength, good ductility and improved corrosion resistance. By cold bulk forming of high nitrogen steels high-strength parts can be manufactured due to the strengthening which is caused by the high strain hardening. However, high tool loads thereby have to be expected and are a major challenge during the production process. Consequently, there is a need for appropriate forming strategies. This paper presents key aspects concerning the process design for the manufacturing of semi-tubular self-piercing rivets made of high-strength steel. The aim is to produce the rivets in several forming stages without intermediate heat treatment between the single stages. Due to the high strain hardening of the material, a two stage forming concept will be investigated. Cup-backward extrusion is chosen as the first process step in order to form the rivet shank without forming the rivet foot. Thus, the strain hardening effects in the area of the rivet foot are minimized and the tool loads during the following process step can be reduced. During the second and final forming stage the detailed geometry of the rivet foot and the rivet head is formed. In this context, the effect of different variations, for example concerning the final geometry of the rivet foot, on the tool load is investigated using multistage numerical analysis. Furthermore, the influence of the process temperature on occurring stresses is analysed. Based on the results of the investigations, an adequate forming strategy and a tool concept for the manufacturing of semi-tubular self-piercing rivets made of high-strength steel are presented. ED - Kuball, Clara-Maria ED - Uhe, Benedikt ED - Meschut, Gerson ED - Merklein, Marion ID - 19976 KW - high nitrogen steel KW - self-piercing riveting KW - joining by forming KW - bulk forming KW - tool design TI - Process design for the forming of semi-tubular self-piercing rivets made of high nitrogen steel VL - 50 ER - TY - GEN AB - Due to the trend towards lightweight design in car body development mechanical joining technologies become increasingly important. These techniques allow for the joining of dissimilar materials and thus enable multi-material design, while thermic joining methods reach their limits. Semi-tubular self-piercing riveting is an important mechanical joining technology. The rivet production, however, is costly and time-consuming, as the process consists of several process steps including the heat treatment and coating of the rivets in order to achieve an adequate strength and corrosion resistance. The use of high nitrogen steel as rivet material leads to the possibility of reducing process steps and hence increasing the efficiency of the process. However, the high tool loads being expected due to the high strain hardening of the material are a major challenge during the rivet production. Thus, there is a need for appropriate forming strategies, such as the manufacturing of the rivets at elevated temperatures. Prior investigations led to the conclusion that forming already at 200 °C results in a distinct reduction of the yield strength. To create a deeper understanding of the forming behaviour of high nitrogen steel at elevated temperatures, compression tests were conducted in a temperature range between room temperature and 200 °C. The determined true stress – true strain curves are the basis for the further process and tool design of the rivet production. Another key factor for the rivet manufacturing at elevated temperatures is the influence of the process temperature on the tribological conditions. For this reason, ring compression tests at room temperature and 200 °C are carried out. The friction factors are determined on the basis of calibration curves resulting from the numerical analysis of the ring compression process. The investigations indicate that the friction factor at 200 °C is significantly higher compared to room temperature. This essential fact has to be taken into account for the process and tool design for the rivet production using high nitrogen steel. ED - Kuball, Clara-Maria ED - Jung, R ED - Uhe, Benedikt ED - Meschut, Gerson ED - Merklein, Marion ID - 19974 KW - High nitrogen steel KW - Self-piercing riveting KW - Joining by forming KW - Bulk forming KW - Strain hardening TI - Influence of the process temperature on the forming behaviour and the friction during bulk forming of high nitrogen steel VL - 1 ER - TY - JOUR AB - As a result of lightweight design, increased use is being made of high-strength steel and aluminium in car bodies. Self-piercing riveting is an established technique for joining these materials. The dissimilar properties of the two materials have led to a number of different rivet geometries in the past. Each rivet geometry fulfils the requirements of the materials within a limited range. In the present investigation, an improved rivet geometry is developed, which permits the reliable joining of two material combinations that could only be joined by two different rivet geometries up until now. Material combination 1 consists of high-strength steel on both sides, while material combination 2 comprises aluminium on the punch side and high-strength steel on the die side. The material flow and the stress and strain conditions prevailing during the joining process are analysed by means of numerical simulation. The rivet geometry is then improved step-by-step on the basis of this analysis. Finally, the improved rivet geometry is manufactured and the findings of the investigation are verified in experimental joining tests. AU - Uhe, Benedikt AU - Kuball, Clara-Maria AU - Merklein, Marion AU - Meschut, Gerson ID - 19973 JF - Production Engineering KW - Self-piercing riveting KW - Joining technology KW - Rivet geometry KW - Multi-material design KW - High-strength steel KW - Aluminium TI - Improvement of a rivet geometry for the self-piercing riveting of high-strength steel and multi-material joints VL - 14 ER -