Simulation-aided development of a robust thermoclinching joining process for hybrid structures with textile reinforced thermoplastic composites and metallic components

摘要

In order to take advantage of the specific structural and functional properties inside a multi-material assembly, it is necessary to provide adapted joining technologies. Therefore, the new joining technology "thermoclinching" was developed to join endless fiber reinforced thermoplastic composites and metallic joining partners. Previous experimental and numerical studies demonstrated the potential of the novel joining technology. In experimental and numerical studies essential geometrical and material parameters influencing the forming behavior are identified and evaluated. Thereby, the inline-thermoclinching technology is developed by integrating the pre-processed steps of cutting and heating into the actual joining process. For structural analysis of the joining zone as well as for quality analysis and validation of the process simulations computer tomography (CT) is used. Furthermore, experimental characterizations of the failure behavior of thermoclinched joints and the development of simulation models as well as strategies for numerical strength analyses are carried out.