Deformationsarme Fügeverbindungen mittels prozessoptimiertem Schneidclinchen

Lightweight materials such as aluminium and ultra-high-strength steel are increasingly being used in modern material mixed design in car body construction. As a fixing method for hybrid joining with structural adhesive, clinching has the advantage over other mechanical joining technologies that different materials can be joined without an auxiliary joining part and pre-hole. Due to the large degree of deformation in the joining partners, strong in-plane and out-of-plane material flows occur during the setting process, which can lead to plastic deformation. The aim of this work is the further development of shear-clinching for low-deformation of aluminium-steel joints. To gain a basic understanding of the joint deformation, the deformation of the joint partners during the setting process is identified step by step. Based on the knowledge gained, the deformation-related influencing factors are investigated experimentally. Thus, optimisation approaches as well as suggested handling methods for the production of a low-deformation shear-clinching joint are derived. For the realisation of the common narrow flange, which is to be characterised as deformation-sensitive due to a small edge distance, a numerically supported tool modification is carried out and subsequently experimentally validated.