Skip to main content
SpringerLink
Log in

Research on the joining of three-layer sheets by flat bottom riveting process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract   

With the widespread application of lightweight materials in aerospace and automotive industries, higher demands are placed on the joining technology of lightweight materials, and the flat bottom riveting process is proposed as new technology. In this study, the material flow of three-layer sheets during the flat bottom riveting process was investigated using experimental methods. The failure modes of the sheets under different loading methods were discussed in tensile and shear tests. The results showed that a double mechanical interlock structure was created among the three-layer sheets. The first mechanical interlock between the upper and middle sheets has higher tensile and shear loads than the second mechanical interlock between the middle and lower sheets. The double mechanical interlock structure has higher joint strength compared to the single mechanical interlock structure formed by two-layer sheets of flat bottom riveting process. In addition, the tensile and shear load application methods can cause different modes of failure of the sheet. Tensile failures and pull-off failures occur with higher tensile loads and shear failures and mixed failures occur with higher shear loads. The first mechanical interlock has a stronger failure energy absorption capacity.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

Data availability

The raw/processed data required to reproduce these findings cannot be shared at this time due to technical or time limitations.

Code availability

Not applicable.

References 

  1. Borsellino C, Di Bella G, Ruisi VF (2007) Study of new joining technique: flat clinching. Key Eng Mater 344:685–692. https://doi.org/10.4028/www.scientific.net/KEM.344.685

    Article  Google Scholar 

  2. Chen C, Zhao S, Han X et al (2017) Investigation of flat clinching process combined with material forming technology for aluminum alloy. Materials 10(12):1433. https://doi.org/10.3390/ma10121433

    Article  Google Scholar 

  3. Chen C, Zhao S, Han X et al (2017) Experimental investigation on the joining of aluminum alloy sheets using improved clinching process. Materials 10(8):887. https://doi.org/10.3390/ma10080887

    Article  Google Scholar 

  4. Qin D, Chen C (2022) Failure behavior and mechanical properties of novel dieless clinched joints with different sheet thickness ratios. J Cent South Univ 29:3077–3087. https://doi.org/10.1007/s11771-022-5120-8

    Article  Google Scholar 

  5. Abe Y, Kishimoto M, Kato T et al (2009) Joining of hot-dip coated steel sheets by mechanical clinching. Int J Mater Form 2(1):291–294. https://doi.org/10.1007/s12289-009-0446-4

    Article  Google Scholar 

  6. Lin P-C, Fang J-C, Lin J-W et al (2020) Preheated (heat-assisted) clinching process for Al/CFRP cross-tension specimens. Materials 13(18):4170. https://doi.org/10.3390/ma13184170

    Article  Google Scholar 

  7. Ma Y, Yang B, Lou M et al (2020) Effect of mechanical and solid-state joining characteristics on tensile-shear performance of friction self-piercing riveted aluminum alloy AA7075-T6 joints. J Mater Process Technol 278:116543. https://doi.org/10.1016/j.jmatprotec.2019.116543

    Article  Google Scholar 

  8. Mori K, Abe Y, Kato T (2012) Mechanism of superiority of fatigue strength for aluminium alloy sheets joined by mechanical clinching and self-pierce riveting. J Mater Process Technol 212(9):1900–1905. https://doi.org/10.1016/j.jmatprotec.2012.04.017

    Article  Google Scholar 

  9. Ren X-q, Chen C, Ran X-k et al (2021) Microstructure evolution of AA5052 joint failure process and mechanical performance after reconditioning with tubular rivet. Trans Nonferr Metal Soc China 31:3380–3393. https://doi.org/10.1016/S1003-6326(21)65736-9

    Article  Google Scholar 

  10. Lin J, Guo T, Su A, et al (2015) Effects of process parameters on sheets warp of clinching based on abaqus. In: 2015 International Conference on Computer Science and Mechanical Automation (CSMA) pp.308–312. IEEE. https://ieeexplore.ieee.org/abstract/document/7371672/

  11. Kaščák L, Mucha J, Spišák E et al (2017) Wear study of mechanical clinching dies during joining of advanced high-strength steel sheets. Strength Mater 49(5):726–737. https://doi.org/10.1007/s11223-017-9918-9

    Article  Google Scholar 

  12. Lee C-J, Kim J-Y, Lee S-K et al (2010) Parametric study on mechanical clinching process for joining aluminum alloy and high-strength steel sheets. J Mech Sci Technol 24(1):123–126. https://doi.org/10.1007/s12206-009-1118-5

    Article  Google Scholar 

  13. Chen C, Zhang H, Peng H et al (2020) Investigation of the restored joint for aluminum alloy. Metals 10(1):97. https://doi.org/10.3390/met10010097

    Article  Google Scholar 

  14. Neugebauer R, Kraus C, Dietrich S (2008) Advances in mechanical joining of magnesium. CIRP Ann 57(1):283–286. https://doi.org/10.1016/j.cirp.2008.03.025

    Article  Google Scholar 

  15. Neugebauer R, Mauermann R, Dietrich S et al (2007) A new technology for the joining by forming of magnesium alloys. Pro Eng 1(1):65–70. https://doi.org/10.1007/s11740-007-0045-5

    Article  Google Scholar 

  16. Mucha J, Kaščák L, Spišák E et al (2011) Joining the car-body sheets using clinching process with various thickness and mechanical property arrangements. Arch Civil Mech Eng 11(1):135–148. https://doi.org/10.1016/S1644-9665(12)60179-4

    Article  Google Scholar 

  17. Lambiase FJM and Design (2015) Mechanical behaviour of polymer–metal hybrid joints produced by clinching using different tools. Mater Des 87:606–618. https://doi.org/10.1016/j.matdes.2015.08.037

    Article  Google Scholar 

  18. Chen C, Wu J, Li H (2021) Optimization design of cylindrical rivet in flat bottom riveting. Thin Wall Struct 168:108292. https://doi.org/10.1016/j.tws.2021.108292

    Article  Google Scholar 

  19. Ang HQ (2021) An overview of self-piercing riveting process with focus on joint failures, corrosion issues and optimisation techniques. Chin J Mech Eng 34(1):1–25. https://doi.org/10.1186/s10033-020-00526-3

    Article  Google Scholar 

  20. Peng H, Chen C, Zhang H et al (2020) Recent development of improved clinching process. Int J Adv Manuf Technol 110(11):3169–3199. https://doi.org/10.1007/s00170-020-05978-4

    Article  Google Scholar 

  21. Chen C, Zhao S, Han X et al (2016) Optimization of a reshaping rivet to reduce the protrusion height and increase the strength of clinched joints. J Mater Process Technol 234:1–9. https://doi.org/10.1016/j.jmatprotec.2016.03.006

    Article  Google Scholar 

  22. Chen C, Li Y, Zhang H et al (2020) Investigation of a renovating process for failure clinched joint to join thin-walled structures. Thin Wall Struct 151:106686. https://doi.org/10.1016/j.tws.2020.106686

    Article  Google Scholar 

  23. Lambiase F, Ko D-CJCS (2017) Two-steps clinching of aluminum and carbon fiber reinforced polymer sheets. Compos Struct 164:180–188. https://doi.org/10.1016/j.compstruct.2016.12.072

    Article  Google Scholar 

  24. Varis J (2006) Economics of clinched joint compared to riveted joint and example of applying calculations to a volume product. J Mater Process Technol 172(1):130–138. https://doi.org/10.1016/j.jmatprotec.2005.09.009

    Article  Google Scholar 

  25. Chen C, Qin D, Ren X et al (2021) Finite element analysis of the cylindrical rivet used in flat clinch-rivet process. J Brazilian Soc Mech Sci Eng 43(12):1–15. https://doi.org/10.1007/s40430-021-03278-w

    Article  Google Scholar 

  26. Lei L, He X, Yu T et al (2019) Failure modes of mechanical clinching in metal sheet materials. Thin Wall Struct 144:106281. https://doi.org/10.1016/j.tws.2019.106281

    Article  Google Scholar 

  27. Chen C, Zhang H, Zhao S et al (2021) Effects of sheet thickness and material on the mechanical properties of flat clinched joint. Front Mech Eng 16(2):410–419. https://doi.org/10.1007/s11465-020-0618-y

    Article  Google Scholar 

  28. Chen C, Ouyang Y, Qin D (2021) Finite element analysis of material flow in flat-rivet clinching process. Int J Adv Manuf Technol 116:1961–1974. https://doi.org/10.1007/s00170-021-07532-2

    Article  Google Scholar 

  29. He X (2017) Clinching for sheet materials. Sci Technol Adv Mater 18:381–405. https://doi.org/10.1080/14686996.2017.1320930

    Article  Google Scholar 

  30. Gerstmann T (2016) Erweiterung der Verfahrensgrenzen des Flach-Clinchens. https://nbn-resolving.org/urn:nbn:de:bsz:ch1-qucosa-208840

  31. Gerstmann T, Awiszus B (2014) Recent developments in flat-clinching. Comput Mater Sci 81:39–44. https://doi.org/10.1016/j.commatsci.2013.07.013

    Article  Google Scholar 

  32. Han X, Zhao S, Liu C et al (2016) Optimization of geometrical design of clinching tools in clinching process with extensible dies. Proc Inst Mech Eng Part C: J Mech Eng Sci 231:3889–3897. https://doi.org/10.1177/0954406216660336

    Article  Google Scholar 

  33. Chen C, Zhang H, Xu Y et al (2020) Investigation of the flat-clinching process for joining three-layer sheets on thin-walled structures. Thin Wall Struct 157:107034. https://doi.org/10.1016/j.tws.2020.107034

    Article  Google Scholar 

  34. Chen C, Li Y, Zhai Z et al (2019) Comparative investigation of three different reforming processes for clinched joint to increase joining strength. J Manuf Process 45:83–91. https://doi.org/10.1016/j.jmapro.2019.06.009

    Article  Google Scholar 

  35. Chen C, Zhao S, Cui M et al (2017) Numerical and experimental investigations of the reshaped joints with and without a rivet. Int J Adv Manuf Technol 88(5):2039–2051. https://doi.org/10.1007/s00170-016-8889-5

    Article  Google Scholar 

  36. He X, Zhao L, Yang H et al (2014) Investigations of strength and energy absorption of clinched joints. Comput Mater Sci 94:58–65. https://doi.org/10.1016/j.commatsci.2014.01.056

    Article  Google Scholar 

  37. Shi C, Li H, Chen C et al (2022) Experimental investigation of the flat clinch–rivet process. Thin Wall Struct 171:108612. https://doi.org/10.1016/j.tws.2021.108612

    Article  Google Scholar 

Download references

Funding

This research work is supported by the National Natural Science Foundation of China (Grant No. 52275398), Central South University Innovation-Driven Research Programme (2023CXQD069), Hunan Provincial Natural Science Foundation for Excellent Young Scholars (Grant No. 2021JJ20059), the Project of State Key Laboratory of High Performance Complex Manufacturing, Central South University (Grant No. ZZYJKT2022-01), Huxiang Young Talents Program of Hunan Province (No.2021RC3024) and Huxiang High-Level Talent Gathering Project of Hunan Province (Grant No. 2021RC5001).

Author information

Authors and Affiliations

  1. Light Alloy Research Institute, Central South University, Changsha, 410083, China

    Chao Chen & Xiao Ouyang

  2. State Key Laboratory of Precision Manufacturing for Extreme Service Performance, Central South University, Changsha, 410083, China

    Chao Chen & Xiao Ouyang

  3. School of Mechanical and Electrical Engineering, Central South University, Changsha, 410083, China

    Chao Chen

Authors
  1. Chao Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Xiao Ouyang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Chao Chen and Xiao Ouyang analyzed the data; Chao Chen contributed reagents/materials/analysis tools; Xiao Ouyang and Chao Chen wrote the paper.

Corresponding author

Correspondence to Chao Chen.

Ethics declarations

Ethical approval

Not applicable.

Consent to participate

Not applicable.

Consent to publish

Not applicable.

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Chen, C., Ouyang, X. Research on the joining of three-layer sheets by flat bottom riveting process. Int J Adv Manuf Technol 127, 459–469 (2023). https://doi.org/10.1007/s00170-023-11410-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11410-4

Keywords

Search

Navigation