Computer-Aided Modeling of the Hot Forming Staking Process Based on Experimental Data

Abstract

As a non-detachable and point-acting joint, thermoplastic staking is primarily used for the production of electronic and sensor elements as well as for the joining of components in the automotive interior and exterior. Commonly, the advantages of staking processes are its cost-efficient and seemingly simple process control. Regarding the industrial application, staking is principally a well-established forming process. However, despite the high number of applications, the joint design and the process settings are mainly based on extensive empirical tests. At present, the FE simulation of these thermoplastic staking processes is not state-of-the-art. Due to these facts, within the frame of the paper, these gaps are to be closed by the computer-aided modeling of the hot forming staking to map the heating and forming behavior of this process close to reality. This procedure demands the associated experimental validation of the simulation. In summary, the numerical model shows high conformity to the experimental data and allows a simulative mapping of the morphological characteristics of the riveted joint as well as indicative statements to the process parameters, which means in particular the minimal heating time for forming and the optimized post-heating time for a morphological homogenization.