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Deformation analysis and processing parameter optimization of roller clinching

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Abstract

Roller clinching is a variation of conventional clinching by using rotational tool movement. The joining quality of roller clinching is significantly affected by tooling geometries and motions. Considering the formation difference of joints at different locations, this paper investigated the deformation features of roller clinching of square joints and utilized multiple linear regression analysis to optimize the processing parameters. It was found that roller geometry has significant impact on the formation of interlocks of the front/rear sides of joints, while the impact on the formation of lateral sides is less. With the increase of roller diameters, the clearance variation of front/rear sides decreases; meanwhile, the separation clearance s at the front side after forming decreases. In the study, when the roller diameter is raised from 35 to 150 mm, the connection strength increases by 44%. If the diameter difference w of rollers increases, the squeezing degree of the front side decreases, and the joining quality increases; however, if the squeezing degree of the rear side increases, then the joining quality of the rear side and s decrease. In the sample, an increase in w by 3 mm enhanced the connection strength by 9%. When the clearance difference t between the rollers increases, the capability to contain metal increases in the rear side. When t increases by 0.6 mm, the connection strength augments by 12%. The separation clearance s of the front side is greatly affected by friction μ, roller diameter, w, and draft angle γ of the lower roller, while the effect of draft angle β of the upper roller on s is small.

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Data availability

The datasets generated and analyzed during the current study are available from the corresponding author on reason-able request.

Code availability

Not applicable.

Abbreviations

R p :

Radius of upper roller

R d :

Radius of lower roller

w :

Diameter difference of the upper and lower rollers

β :

Draft angle of the upper roller

γ :

Draft angle of the lower roller

d :

Distance between the centers of the upper and lower rollers

ω :

Angular velocity of the rollers

W p :

The thickness of the upper roller punch in the axial direction of the roller

x :

Thickness of joint bottom

H d :

Die depth in the radial direction of the lower roller

h :

The height of the punch in the radial direction of the upper roller

c :

Depth of the lower roller cavity

T u :

Interlock

T pn :

The minimum thickness of the upper sheet in the axial direction of the roller

T dn :

The minimum thickness of the lower sheet in the axial direction of the roller

ΔL f :

Front clearance between the rollers, when θ = 0

ΔL e :

Rear clearance between the rollers, when θ = 0

t :

Difference between ΔLf and ΔLe

θ :

Rotation angle of the rollers

θ 1 :

Rotation angle of the rollers, when lower plate contacts the lower roller cavity

θ A :

Intersection angle of rotation radius of point A to y-direction, when θ = 0

θ B :

Intersection angle of rotation radius of point B to y-direction, when θ = 0

L A :

Distance from point A to the front side of lower roller

L B :

Distance from point B to the front side of upper roller

R A :

Rotation radius of point A

R B :

Rotation radius of point B

μ :

Friction coefficient

s :

Separation clearance at the front side after forming

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Funding

This project is supported by the Natural Science Foundation of Chongqing (Grant No. cstc2018jcyjAX0159 and cstc2020jcyj-msxmX0420).

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Authors and Affiliations

  1. College of Materials Science and Engineering, Chongqing University, Chongqing, 400044, China

    Youcheng Pan, Tong Wen, Yin Zhou, Jianhao You, Haoxing Tang & Xia Chen

Authors
  1. Youcheng Pan
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  2. Tong Wen
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  3. Yin Zhou
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  4. Jianhao You
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  5. Haoxing Tang
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  6. Xia Chen
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Contributions

Youcheng Pan: conceptualization, formal analysis, writing. Tong Wen: project administration, supervision, reviewing, editing. Yin Zhou: simulation, investigation. Jianhao You, Haoxing Tang and Xia Chen: experiment data analysis.

Corresponding author

Correspondence to Tong Wen.

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Pan, Y., Wen, T., Zhou, Y. et al. Deformation analysis and processing parameter optimization of roller clinching. Int J Adv Manuf Technol 116, 1621–1631 (2021). https://doi.org/10.1007/s00170-021-07215-y

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