• Journal of Welding and Joining
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• v.33 no.3
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• pp.75-80
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• 2015

Self-piercing riveting is an joining method of advanced high strength steels (AHSS) and other dissimilar materials. It has attracted considerable interest from the automotive industry. The SPR has become an interesting alternative joining technique for difficult to weld materials such as steels and aluminium alloys. In this paper, self-piercing rivet and anvil for SPR were designed for the joining conditions with AHSS and aluminium alloy. Various conditions of SPR were simulated for the design of rivets and anvils. The simulated results were in good agreement with experimental ones. As a result, over HV500 rivet is desirable to joint SPFC780 AHSS and aluminum alloy.

• Transactions of Materials Processing
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• v.12 no.8
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• pp.702-709
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• 2003

In the automotive industry hydroforming of sheet metal pairs have received special attention because materials for various sheet metal components of vehicles have changed into the high strength steel, aluminum, and titanium blank having low formability. Uniform deformation over the whole region is a main advantage in the sheet hydroforming process. Because upper and lower parts could be produced simultaneously with one tool, hydroforming of sheet metal pairs is competitive in reducing the lead-time and development cost. In this paper, the multi-stage hydroforming process of sheet pair is proposed in order to increase the formability of a structural part like the oil pan shape. The upper die for forming oil pan shape is divided into two parts which can move separately. By the finite element simulation, the design parameters such as geometry of the tool and detailed specification of hydraulic pump were calculated and verified. For the strict comparison of the proposed process, the blank holding force is kept to a constant value during deformation by hydraulic valve. The deformed shape and strain distribution of the manufactured parts with the proposed process are compared with the results of simulation. In the multi-stage hydroforming process, maximum thickness strain was improved by more than 30 percent.

• Korean Journal of Metals and Materials
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• v.48 no.5
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• pp.387-393
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• 2010

High-strength aluminum alloy sheets with high magnesium contents were fabricated by a strip caster equipped with an asymmetric nozzle, which has been proven to be effective for reducing surface defects and internal segregation. 4 mm thick as-cast sheets consisting of fine dendrites and minor $Al_{8}Mg_{5}$ segregation were hot-rolled successfully to 1 mm sheets and subsequently annealed at various temperatures. The sheet revealed the tensile strength and elongation of 306 MPa and 34%, respectively, when it was rolled at 250${^{\circ}C}$ and subsequently annealed at 475${^{\circ}C}$, which exhibits the feasibility of the practical application for autobodies. The observed mechanical properties were explained on the basis of the microstructural characteristics of the alloy sheets.

• Korean Journal of Materials Research
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• v.21 no.12
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• pp.655-659
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• 2011

An ultrafine grained complex aluminum alloy was fabricated by an accumulative roll-bonding (ARB) process using dissimilar aluminum alloys of AA1050 and AA5052 and subsequently annealed. A two-layer stack ARB process was performed up to six cycles without lubricant at an ambient temperature. In the ARB process, the dissimilar aluminum alloys, AA1050 and AA5052, with the same dimensions were stacked on each other after surface treatment, rolled to the thickness reduction of 50%, and then cut in half length by a shearing machine. The same procedure was repeated up to six cycles. A sound complex aluminum alloy sheet was fabricated by the ARB process, and then subsequently annealed for 0.5h at various temperatures ranging from 100 to $350^{\circ}C$. The tensile strength decreased largely with an increasing annealing temperature, especially at temperatures of 150 to $250^{\circ}C$. However, above $250^{\circ}C$ it hardly decreased even when the annealing temperature was increased. On the other hand, the total elongation increased greatly above $250^{\circ}C$. The hardness exhibited inhomogeneous distribution in the thickness direction of the specimens annealed at relatively low temperatures, however it had a homogeneous distribution in specimens annealed at high temperatures.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.6
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• pp.691-698
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• 2012

The joining of aluminum and HSS (high-strength steel) by the conventional clinching process is limited by the low formability of HSS. Defects in the clinching joint, such as necking of the upper sheet, cracks, and lack of interlocking, are produced by the different ductility properties of HSS and aluminum. In this study, we propose the hole clinching process for joining Al6061 and SPFC440, in which deformation of SPFC440 is avoided by drilling a hole in the SPFC440. The dimensions of the interlocking in the hole-clinched joint necessary to provide the required joint strength were determined. Based on the volume constant of the hole clinching process, the shapes of the tools were designed by finite element (FE)-analysis. A hole clinching experiment was performed to verify the proposed process. A cross-section of the joint showed good agreement with the results of the FE-analysis. The lap shear strength was found to be 2.56 kN, which is higher than required joint strength.

• Design & Manufacturing
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• v.16 no.4
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• pp.46-51
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• 2022

The piercing process of creating holes in sheet metals for mechanical fastening generates high shear force. Real-time monitoring technology could predict tool damage and product defects due to this severe condition, but there are few applications for piercing high-strength aluminum. In this study, we analyzed the load signal to predict the punch's wear level during the process with a piezoelectric sensor installed piercing tool. Experiments were conducted on Al6061 T6 with a thickness of 3.0 mm using piercing punches whose edge angle was controlled by reflecting the wear level. The piercing load increases proportionally with the level of tool wear. For example, the maximum piercing load of the wear-shaped punch with the tip angle controlled at 6 degrees increased by 14% compared to the normal-shaped punch under the typical clearance of 6.7% of the aluminum piercing tool. In addition, the tool wear level increased compression during the down-stroke, which is caused by lateral force due to the decrease in the diameter of pierced holes. Our study showed the predictability of the wear level of punches through the recognition of changes in characteristic elements of the load signal during the piercing process.

• Transactions of the Korean Society of Automotive Engineers
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• v.2 no.2
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• pp.95-102
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• 1994

Aluminum sheet application to automobile body panels has now become an important objective to meet the requirements of automobile weight reduction. As the Mg content in Al-Mg based alloys increased up to 7.19%, the strength and elongation increased. For instance. Al-7.19Mg alloy had a high strength of 305MPa and a high elongation of 35%. A study was also made to investigate the interrelation between grain size and tensile properties with varying the contents of Mg, Ti and Zr elements and annealing conditions. The yield stress decreased as the grain size increased, which increased the uniform elongation. The strain hardening exponents n increased as the Mg content increased, which depended on the increasing difficulties of the cross slip of dislocation.

• Transactions of Materials Processing
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• v.31 no.6
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• pp.351-364
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• 2022

The yield criterion, or called yield function, plays an important role in the study of plastic working of a sheet because it governs the plastic deformation properties of the sheet during plastic forming process. In this paper, we propose a modified version of previous anisotropic yield function (Trans. Mater. Process., 31(4) 2022, pp. 214-228) based on J2 and J3 stress invariants. The proposed anisotropic yield model has the 6th-order of stress components. The modified version of the anisotropic yield function in this study is as follows. f(J₂⁰,J₃⁰) ≡ (J₂⁰)³ + α(J₃⁰)² + β(J₂⁰)^3/2 × (J₃⁰) = k⁶ The proposed anisotropic yield function well explains the anisotropic plastic behavior of various sheets such as aluminum, high strength steel, magnesium alloy sheets etc. by introducing the parameters α and β, and also exhibits both symmetrical and asymmetrical yield surfaces. The parameters included in the proposed model are determined through an optimization algorithm from uniaxial and biaxial experimental data under proportional loading path. In this study, the validity of the proposed anisotropic yield function was verified by comparing the yield surface shape, normalized uniaxial yield stress value, and Lankford's anisotropic coefficient R-value derived with the experimental results. Application for the proposed anisotropic yield function to AA6016-T4 aluminum and DP980 sheets shows symmetrical yielding behavior and to AZ31B magnesium shows asymmetric yielding behavior, it was shown that the yield locus and yielding behavior of various types of sheet materials can be predicted reasonably by using the proposed anisotropic yield function.

• Korean Journal of Materials Research
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• v.29 no.6
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• pp.392-397
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• 2019

A cold roll-bonding process is applied to fabricate an AA6061/AA5052/AA6061 three-layer clad sheet. Two AA6061 and one AA5052 sheets of 2 mm thickness, 40 mm width, and 300 mm length are stacked, with the AA5052 sheet located in the center. After surface treatment such as degreasing and wire brushing, sample is reduced to a thickness of 1.5 mm by multi-pass cold rolling. The rolling is performed at ambient temperature without lubricant using a 2-high mill with a roll diameter of 400 mm at rolling speed of 6.0 m/sec. The roll bonded AA6061/AA5052/AA6061 complex sheet is then hardened by natural aging(T4) and artificial aging(T6) treatments. The microstructures of the as-roll bonded and age-hardened Al complex sheets are revealed by optical microscopy; the mechanical properties are investigated by tensile testing and hardness testing. After rolling, the roll-bonded AA6061/AA5052/AA6061 sheets show a typical deformation structure in which grains are elongated in the rolling direction. However, after T4 and T6 aging treatment, there is a recrystallization structure consisting of coarse equiaxed grains in both AA5052 and AA6061 sheets. The as roll-bonded specimen shows a sandwich structure in which an AA5052 sheet is inserted into two AA6061 sheets with higher hardness. However, after T4 and T6 aging treatment, there is a different sandwich structure in which the hardness of the upper and lower layers of the AA6061 sheets is higher than that of the center of the AA5052 sheet. The strength values of the T4 and T6 age-treated specimens are found to increase by 1.3 and 1.4 times, respectively, compared to that value of the starting material.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.38 no.7
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• pp.735-742
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• 2014

A self-piercing rivet (SPR) is a mechanical component for joining dissimilar material sheets such as those of aluminum alloy and steel. Unlike conventional rivets, the SPR directly pierces sheets without the need for drilling them beforehand. However, the regular SPR can undergo buckling when it pierces a high-strength steel sheet, warranting the design of a helical SPR. In this study, the joining and forging processes using the helical SPR were simulated using the commercial FEM code, DEFORM-3D. High-tensile-strength steel sheets of different strengths were joined with aluminum alloy sheets using the designed helical SPR. The simulation results were found to agree with the experimental results, validating the optimal design of a helical SPR that can pierce high-strength steel sheets.