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Numerical simulation of mechanical joining of three DP600 and DC06 steel sheets

Cmorej Denis, Kaščák Ľuboš

Advances in Mechanical and Materials Engineering

2023

Vol. 40, nr 1

23-29

There are many reasons to utilize various grades of steel in car body production. Automotive producers tend to choose steels with great formability and the capacity to absorb impact energy. The dominant method used for joining car body sheets has for many years been resistance spot welding, but the use of various steel sheets leads to research into alternative joining methods. Mechanical joining - clinching, is the innovative method to join these materials. Numerical simulation tools are used to optimize the joining of materials. Simufact Forming software was used to analyse the clinching joining of three sheets of material DP600 and DC06. According to the axisymmetric character of the mechanical joining process, the simulation was stream-lined to a 2D representation. The results of the simulation of the mechanical joining process were compared with the real samples prepared for metallographic observation.

Istnieje wiele powodów dla których warto wykorzystywać różne gatunki stali do produkcji karoserii. Producenci motoryzacyjni wykorzystują blachy stalowe o dużej plastyczności i zdolności pochłaniania energii uderzenia. Od wielu lat dominującą metodą łączenia blach karoserii samochodowej jest punktowe zgrzewanie oporowe. Zastosowanie różnych blach stalowych prowadzi do badań nad alternatywnymi metodami łączenia. Łączenie mechaniczne – przetłaczanie, to innowacyjna metoda łączenia tych materiałów. Numeryczne narzędzia symulacyjne służą do optymalizacji łączenia materiałów. Oprogramowanie Simufact Forming zostało wykorzystane do analizy łączenia przez przetłaczanie trzech arkuszy materiałów DP600 i DC06. Zgodnie z osiowosymetrycznym charakterem procesu łączenia mechanicznego, symulacja została uproszczona do reprezentacji 2D. Wyniki symulacji procesu łączenia mechanicznego porównano z rzeczywistymi próbkami przygotowanymi do obserwacji metalograficznych.

Joining the High-Strength Steel Sheets Used in Car Body Production

Kaščák Ľuboš, Cmorej Denis, Spišák Emil, Slota Ján

Advances in Science and Technology. Research Journal

2021

Vol. 15, no 1

184--196

Nowadays, there are several important reasons for using high-strength sheets in the manufacturing of car bodies. Car manufacturers choose the steel with good formability, fatigue resistance and ability to absorb impact energy. Microalloyed steels and dual-phase steels are the materials which fulfil the above-mentioned criteria. The application of high-strength sheets has led to the development of new materials joining techniques. Mechanical joining, such as clinching, is the innovative technique to join these progressive materials. Materials of different thicknesses can be joined by clinching. The paper focuses on the comparison of the properties of the joints made by clinching and resistance spot welding. The application of resistance spot welding is still the most used joining method in car body production. These properties were investigated by tensile test and metallographic observation. The HCT600X+ZF, HCT600X+Z and HX420LAD+Z steel sheets were used for the experiments. The results of tensile test show that the values of load-bearing capacity of clinched joints reached from 3900 N to 5900 N and the resistance spot welded joints reached the values of load-bearing capacity from 12000 N to 19500 N. In comparison to the resistance spot welded joints, the clinched joints reached from 32 to 48% of load-bearing capacity.