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Hole 클린칭을 이용한 고장력강판과 Al6061 이종소재의 접합
안남식(Nam-sik Ahn),이찬주(Chan-Joo Lee),이정민(Jung-Min Lee),고대철(Dae-Cheol Ko),이선봉(Seon-Bong Lee),김병민(Byung-Min Kim) 대한기계학회 2012 大韓機械學會論文集A Vol.36 No.6
일반적인 클린칭 접합공정에서 고장력강과 알루미늄의 이종소재간의 접합시 고장력강의 낮은 연신율과 높은 강도로 인해 클린칭 접합시 파단이 발생하거나 높은 클린칭 접합하중이 요구된다. 이러한 문제점을 해결하기 위해 본 연구에서는 클린칭 접합시 고장력강의 변형없이 알루미늄의 변형만을 이용한 홀 클린칭 접합공정을 개발하였다. 고장력강에 홀가공을 적용하여 고장력강의 변형을 배제하였다. 홀 클린칭 접합의 요구접합강도를 기초로 클린칭 접합의 기하학적 구속량을 결정하였으며, 홀 클린칭 금형의 형상은 성형체적 일정조건을 이용하여 설계하였다. 설계된 클린칭 접합공정의 유효성을 평가하기 위해 유한요소해석을 수행하여, 홀 클린칭 접합이 가능함을 확인하였다. 또한 홀 클린칭 접합의 접합강도는 인장전단시험을 통하여 평가하였다. 홀 클린칭 접합강도는 2.56kN 으로 요구접합강도와 비교하여 동등수준 이상의 값을 가짐을 확인하였다. 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.
황빛나(B.N. Hwang),이찬주(C.J. Lee),김재영(J.Y. Kim),이상곤(S.K. Lee),고대철(D.C. Ko),김병민(B.M. Kim) 대한기계학회 2009 대한기계학회 춘추학술대회 Vol.2009 No.5
Hybrid clinching is a combination of adhesive bonding and clinching joining method to attach similar or dissimilar materials. During the hybrid clinching process, the adhesive applied on each adherend and reduce d the friction between adherends as lubricant. In this study, the effect of frictional characteristics of adhesive on deformation of adherend in clinching process was investigated by using the FE-analysis. From the result of FE-analysis, the neck thickness was increased and undercut was decreased with increasing of frictional coefficient. The flat friction test was performed to evaluate the frictional coefficient of adhesive. And hybrid clinching experiment was performed and compared its cross section with FE-analysis result with the frictional coefficient of adhesive. It had good agreement between experiment and FE-analysis.
구조용 접착제를 적용한 하이브리드 클린칭 접합의 충돌 성능 평가
황빛나(Binna Hwang),김병민(Byung-Min Kim),이찬주(Chan-Joo Lee) 한국자동차공학회 2010 한국자동차공학회 학술대회 및 전시회 Vol.2010 No.11
The objective of this study is to evaluate the crashworthiness of hybrid clinching with structured adhesive. To compare crashworthiness by joining method, crash boxes were made of aluminum 5052 alloy and joined using clinched joining and hybrid clinched joining respectively. In advance, joint of clinching and adhesive were realized with cohesive zone model (CZM) in ABAQUS/CAE and the impact analysis has been performed. Then real impact test was performed under the identical condition of FE-analysis. Penetration depth, maximum impact load and energy absorption at the point where 50% of total displacements were compared to assess crashworthiness. In result, Crashworthiness of crash body joined using hybrid clinching is larger 20% or more than those by conventional clinching.
Al5052 합금소재와 고장력강판의 이종재료 클린칭 접합특성
이찬주(Chan Joo Lee),이상곤(Sang Kon Lee),이선봉(Seon Bong Lee),김병민(Byung Min Kim) 대한기계학회 2010 大韓機械學會論文集A Vol.34 No.8
차체 경량화를 위해 알루미늄과 같은 경량금속의 사용은 이종소재 사용은 새로운 접합기술을 요구한다. 클린칭 접합은 이종소재 접합기술 중의 하나로 접합소재의 강도차이에 의해 접합특성이 달라진다. 본 연구에서는 Al5052 합금소재에 대한 고장력강판(SPFC440, 590, 780)에 대한 클린칭 접합특성을 평가하였다. 유한요소해석과 인장전단시험을 통해 클린칭 접합특성인 클린칭 접합의 기학적 구속량과 접합강도를 평가하였다. 상부소재가 고장력강판인 경우, SPFC780 은 상부소재의 네킹으로 클린칭 접합이 불가능하였다. 또한 상부소재의 강도가 증가함에 따라 접합강도가 증가하는 특성을 나타내었다. 하부소재가 고장력강판인 경우, 기하학적 구속량인 목두께 및 언더컷과 접합강도는 하부소재의 강도가 증가함에 따라 감소하는 경향을 나타내었다. For manufacturing modern cars, so-called multi-materials, such as aluminum alloy with high-strength steels, are used. For obtaining such materials, a new joining method is required to achieve the multi-material design. Mechanical clinching is one of joining methods used to join the dissimilar materials. The objective of this study is to investigate the characteristics of mechanical clinching of Al5052 alloy to high-strength steels (SPFC440, 590, 780). Using FE-analysis and clinching experiment, the joinability of Al5052 alloy to high-strength steel is evaluated by geometrical shape of mechanical clinched joint, such as neck-thickness and undercut. Further, the joint strength is evaluated by performing a single-lap shear test. The upper high-strength steel SPFC780 was not clinched because of the necking of the upper sheet. The joint strength increased with increasing strength of the upper sheet. For the lower high-strength steel sheet, the joinability and joint strength decreased with increasing strength of the lower sheet
A6451 알루미늄 및 용융아연도금강판의 클린칭 접합특성 및 접합기술의 차체 부품 적용 연구
권의표,박현경 한국기계기술학회 2018 한국기계기술학회지 Vol.20 No.6
In this study, clinching characteristics of aluminum and galvanized steels were investigated for the application of clinching as a joining technique to aluminum wheelhouse assembly. A6451 aluminium alloy and galvanized steel sheets were joined by hybrid joining(clinching + adhesive bonding). Tensile-shear load and fracture mode of hybrid joints were investigated. Maximum tensile-shear load of hybrid joints was about six times higher than that of clinched joints without adhesive. Energy absorption values of hybrid joints were higher than those of clinched joints without adhesive as well as resistance spot welded steel joints. Developed aluminum wheelhouse assembly showed higher static stiffness than the existing steel parts. Aluminum wheelhouse inner panel unit was 44% lighter than the steel unit, and the final assembled aluminum wheelhouse was 14.6% lighter than the existing steel parts.
이찬주(C.J. Lee),김재영(J.Y. Kim),이상곤(S.K. Lee),고대철(D.C. Ko),H. Schafer,김병민(B.M. Kim) 한국소성가공학회 2009 한국소성가공학회 학술대회 논문집 Vol.2009 No.5
The purpose of this study is investigating the joint characteristics of advanced high strength steel DP780 and Al5052 alloy sheet in the clinching process. It is difficult to join the advanced high strength with light-weight materials like aluminum alloy, because of low formability of DP780. The defects of clinching joint such as necking of the upper sheet, cracks of the lower sheet and no interlocking were occurred by different ductility between advanced high strength steel and aluminum alloy. The clinching conditions should be optimized to interlock without andy defects. In this study, the effect of process parameters of clinching process on joinability of advanced high strength steel with Al5052 alloy was investigated by using FE-analysis. From the result of FE-analysis, the clearance between clinching punch and die, die depth and the shape of die cavity mainly affected the joinability of advanced high strength steel with Al5052 alloy.
김재영(Jae Young Kim),이찬주(Chan Joo Lee),이상곤(Sang Kon Lee),고대철(Dae Cheol Ko),김병민(Byung Min Kim) 대한기계학회 2008 대한기계학회 춘추학술대회 Vol.2008 No.5
Hybrid joining is a combination of two or more fastening methods employed to attach similar or dissimilar materials. One example is a mechanical clinching joint that is also bonded with adhesive. This hybrid joining could provide a compromise between a familiar mechanical attachment that has proven reliability, and the reduction of problematic issues such as stress concentrations and crack nucleation sites introduced by using mechanical fasteners with polymeric composites. In this study, the effect of adhesive on the joining strength and the deformation behavior of substrate material for the clinching with adhesive hybrid joining process are investigated through the experiment. Meal flow of upper sheet toward opposite direction of punch stroke was constrained by adhesive. And undercut was deformed more easily in hybrid clinching process than common clinching process.
황빛나(Binna Hwang),김병민(Byung-Min Kim),이찬주(Chan-Joo Lee),이상곤(Sang-Kon Lee) 한국자동차공학회 2010 한국자동차공학회 학술대회 및 전시회 Vol.2010 No.11
The automotive industry has made an effort to develop light-weight auto-body structures for the purpose of increasing the fuel efficiency of vehicles. To this requirement the consumed quantity of light-weight material like as aluminum has increased. Using light-weight material effectively needs new design method for multi-material. The objective of this study is to evaluate the joint characteristics of multi-point hybrid clinched joint. FE-analysis of hybrid clinching with multi-point was performed using cohesive zone model (CZM) in ABAQUS/CAE. T-peel specimen of hybrid clinching with two clinched joint was proposed and there were two variables distance between starting point of peel and first clinched joint (P₁) and distance between two clinched joint (P₂) that can effect on joining strength. In result, P₂ have no effect on initial joining strength if P₁ be fixed and the longer P2, the bigger fracture energy of specimen. And the fracture energy was increased steadily until it has certain P1 and then it was dropped rapidly. In this case, strength growing effect of clinched joint was inadequate when P₁ has more over 60 ㎜.