无铆钉铆接的工艺研究

华东交通大学

硕士学位论文

无铆钉铆接的工艺研究

姓名：陈兴茂

申请学位级别：硕士

专业：机械制造及其自动化指导教师：黄志超

20080418

无铆钉铆接的工艺研究

摘要

随着家电及汽车等机械行业的发展和竞争的加剧，这些领域越来越追求加工制造的自动化及高效、快捷性，家电和汽车等机械产品中有不少板料连接件，而无铆钉铆接很适合实现自动化，以提高制造的高效、快捷性，降低生产成本，降低劳动强度。而且无铆钉铆接疲劳强度比点焊高，对于汽车等处于振动工况的机械产品是一个必备的优点。要提高汽车的经济性，可以采用铝镁合金等轻型材料，常用的点焊难于连接，而无铆钉铆接能进行较好连接。

本文首先利用DEFORM-2D有限元软件建立无铆钉铆接有限元模型，对铆接过程进行有限元模拟，分析铆接成形过程中的五个阶段。对模拟过程的应力应变进行了分析，结果表明应力应变主要集中在凸模下面板料及上板料嵌入下板料的镶嵌部分。研究了铆接成形过程中的载荷-行程变化趋势。

其次对不同厚度板料的组合进行模拟，对模拟结果分析，得到影响铆接接头性能主要工艺参数：凸模和凹模形状及尺寸，被铆接的上、下板料的厚度，上、下板料的材料，被铆接板料的机械性能等；并提出制定工艺时的注意事项。

最后分析了凹模深度、凹模环形凹槽深度、凸模圆角大小、上下层板料放置顺序（包括厚度不同和材料不同）对无铆钉铆接接头性能的影响。提出在此情况下凸模和凹模形状的设计原则，为实际设计模具提供了参考。利用多种组合的有限元模拟结果和实验结果，对上、下板料厚度改变情况下铆接接头性能缺陷进行分析和提出解决方案，对无铆钉铆接工艺的制定具有一定的指导意义。

关键词：有限元模拟，无铆钉铆接，DEFORM

STUDY OF CLINCHING TECHNOLOGY

ABSTRACT

With the development and intense competition of machinery industry, such as household appliances and automotive industries.It demands to manufacture more automationally and efficiently.There are a lot of metal sheets connectors in the household electrical appliances, vehicles, and other machinery products, clinching is very suitable to achieve efficient manufacture, lower production costs, and less labor intensity. There is higher fatigue strength of clinching than the spot welding.It is a definite advantage to have the high fatigue shength for the automotive and other mechanical products that serve in the vibration condition. To improve the economics, lightweight materials such as aluminium-magnesium alloy are used in automotive industry, and the common spot welding is difficult to connect them, clinching is the better choice.

Firstly, finite element model of clinching is established on DEFORM-2D software. The finite element simulation of the clinching process is carried out, and five stages of forming process of the riveting are analyzed. Distribution of stress and strain during forming process are analyzed.The results show that stress and strain are mainly concentrated on the sheet under the punch and the mosaic part that the upper sheet embedded into the bottom sheet. This paper has studied trendency of the load-stroke curve.

Secondly, the specimens with different thickness sheets (upper sheet and lower sheet) are simulated, and the simulation results are analyzed. The main technology parameters which influence the performance of riveted joint are obtained, these parameters are the shape and size of punch and concave mold, the thickness of the upper sheet and bottom sheet，the material of the sheets，the mechanical properties of the riveted metal sheet，and so on. And the attention matters of the technology are proposed.

Finally, the effect of the depth of the concave mold, the groove depth of the ring in the concave mold, punch fillet size and laying order of the matal sheets (different thickness and different material) that influence joint performance of clinching are analyzed. Moreover, the principles of designing punch and concave mold shape are proposed. This can provide some references for mold design.Making use of the finite element simulation results and the experiment results of the many kinds of combinations, the performance flaws and the solutions of clinching are forecasted. This can provide certain references to the practical application of clinching.

Key Words:numerical simulation, clinching, DEFORM