Precision Joining of Steel-Aluminum Hybrid Structure by Clinching Process

M.I.S. Ismail; A.S. Buang

M.I.S. Ismail Universiti Putra Malaysia
A.S. Buang Politeknik Banting Selangor

Abstract

Clinching joining has become an alternative technique to conventional spot welding. This innovative joining technology can reduce the production costs and cycle times, and also offers a great prospective for a new product design and manufacturing. Without a better understanding on physical phenomena associated with the clinching process, the correcting unacceptable clinched joint is extremely costly and impossible for some cases. In this study, the overlap joining of low carbon steel and aluminum alloy in clinching process was experimentally and numerically investigated. The tensile-shear strength of overlap-clinched joints was evaluated by tensile-shear test. This test also was used to study the deformation and failure of clinched joints under tensile-shear loading. The results showed that the higher press load has a great influence for achieving better interlocking between steel-aluminum hybrid structures. Insufficient interlocking and thin neck thickness lead to the failure of clinched joints. It also was confirmed that the most critical region of the clinching tool located at the radius corner of punch and die. Development of simplified engineering approaches based on numerical simulation and correlations with experimental data could be very beneficial to industrial applications.

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Author Biographies

M.I.S. Ismail, Universiti Putra Malaysia

Mohd Idris Shah Ismail received his PhD degree in Mechanical Engineering from Okayama University, Japan in 2012. His research work began in 2004 while he was pursuing his Master’s degree in Mechanical Engineering at the Universiti Malaya. His research interests include non-traditional machining, process simulation and modeling, and intelligent manufacturing. He is currently a senior lecturer in Department of Mechanical and Manufacturing Engineering at the Universiti Putra Malaysia.

A.S. Buang, Politeknik Banting Selangor

Ahmad Salleh Buang received his Master degree in Manufacturing Systems Engineering from Universiti Putra Malaysia in 2017. His research interests include welding process, clinching process, and non-destructive testing. He is currently a lecturer in Department of Mechanical Engineering at the Politeknik Banting Selangor.

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