Study On The Steel-Aluminum Plastic Clinching of The Inclined Wall Die

Aim: ing at the problems of low strength and unsatisfactory connection quality of plastic clinching of heterogeneous lightweight materials for the cars body, the Q235 steel sheets, and 5052 aluminum alloy sheets were taken as the research objects, and the inclined wall die for plastic clinching was designed based on the deformation and flow characteristics of sheets in the plastic clinching process. The elastic-plastic finite element numerical simulation and experimental research were used to analyze the plastic clinching process of the inclined wall die, and the failure mode and mechanism of the clinching joints in the shear and peel experiment were deeply studied. The results show that the inclined wall die can effectively increase the interlock value of the joints and reduce the maximum joining force during the clinching process under the condition of ensuring the neck thickness of the joints. When the inclined wall angle α increases from 90° to 100°, the interlock value increases by 38.9%, and the maximum joining force decreases by 8.3%. The influence of inclined wall structure on joint quality can be divided into extrusion stage, radial inflow stage, and stability stage. The comparison between the clinching experiment and the finite element results shows that the two results are in good agreement, which proves that the finite element model of plastic clinching of inclined wall die has a high degree of credibility, and verifies the feasibility of practical application of inclined wall die. Finally, under shear and peel loads, the main failure mode of the joints is separation failure.