铝合金-胶膜压印/粘接复合连接工艺及接头失效分析

doi:10.7527/S1000-6893.2022.28029

Abstract

Abstract:

Hot melt adhesive film was used as adhesive to carry out the experimental research on the composite bonding process of clinch-bonding. Based on Box-Behnken Design （BBD） method， the multiple regression equation between factors （punch pressure， film thickness， sheet hardness） and response values （energy absorption value， failure load） was established， and the internal relationship between factors and response values was analyzed. Combined with the finite element model of mechanical internal locking structure of joint， the fracture failure mode of joint was investigated. The results show that the multiple regression model has high significance and high fitting degree， and the maximum error of energy absorption value and failure load between the experimental value and the predicted value is 7.9% and 11.42%， which verifies the reliability of the model. The punch pressure is positively correlated with energy absorption value and failure load， and the influence of film thickness on energy absorption value and failure load decreases first and then increases. The mechanical properties of the joint are obviously improved by adding film. When the joint is under tension， the failure mode is mainly pull-off failure and mixed failure （pull-off and neck fracture occur simultaneously）， and the finite element analysis is in good agreement with the test.

Key words: clinching, hot melt adhesive film, composite connection, regression model, mechanical properties, finite element simulation

CLC Number:

V261.2⁺8

Jiangbo CHEN, Kai ZENG, Baoying XING, Hongshen ZHANG, Yanfang DING, Xiaocong HE. Aluminum alloy clinch-bonding with hot melt adhesive film and joint failure analysis[J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(14): 428029.

Figures/Tables 15

Fig.1

Fig.2

Fig.3

Table 1

Design of test factors and levels

因素编码值	冲压力 $x 1$ /kN	胶膜厚度 $x 2$ /mm	板材硬度 $x 3$ （HRB）
-1	37.2	0.06	18
0	44.6	0.10	32
1	52.6	0.15	56

Table 1

Table 2

Testing schemes and results of clinch-bonded joints

组号	冲压力 $x 1$ /kN	胶膜厚度 $x 2$ /mm	板材硬度 $x 3$ （HRB）	失效载荷 $y 1$ /N	能量吸收值 $y 2$ /J
1	44.6	0.06	56	7 517.9	5.2
2	37.2	0.10	18	5 706.4	5.9
3	44.6	0.10	32	6 067.5	5.0
4	37.2	0.15	32	6 064.1	7.8
5	52.6	0.10	18	5 888.4	5.3
6	44.6	0.06	18	5 815.6	5.4
7	37.2	0.06	32	5 697.9	7.1
8	52.6	0.06	32	6 085.5	5.8
9	52.6	0.10	56	7 656.3	5.8
10	44.6	0.10	32	5 521.8	6.3
11	44.6	0.15	56	7 694.6	6.1
12	52.6	0.15	32	6 127.2	7.6
13	44.6	0.15	18	5 971.4	7.8
14	37.2	0.10	56	5 908.1	3.7
15	44.6	0.10	32	6 249.8	6.2

Table 2

Table 3

Variance analysis of model

目标量	因素	平方和 $S s$	自由度 $d f$	均方差 $M s$	$F$	$P$
失效载荷	模型	$6.507 × 106$	6	$1.084 × 106$	9.47	0.002 8
	$x 1$	$9.422 × 105$	1	$9.422 × 105$	8.42	0.020 9
	$x 2$	68 535.27	1	68 535.27	0.60	0.461 5
	$x 3$	$3.724 × 106$	1	$3.724 × 106$	32.50	0.000 5
	$x 1 x 3$	$7.248 × 105$	1	$7.248 × 105$	6.33	0.036 1
	$x 22$	$2.541 × 105$	1	$2.541 × 105$	2.22	0.174 8
	$x 32$	$5.448 × 105$	1	$5.448 × 105$	4.76	0.060 8
	失拟项	$6.295 × 105$	6	$1.049 × 105$	0.73	0.676 0

能量吸收值	模型	15.62	6	2.60	7.70	0.005 5
	$x 1$	0.08	1	0.08	0.23	0.645 1
	$x 2$	4.29	1	4.29	12.69	0.007 4
	$x 3$	1.56	1	1.56	4.60	0.064 4
	$x 1 x 3$	2.24	1	2.24	6.62	0.033 0
	$x 22$	3.69	1	3.69	10.92	0.010 8
	$x 32$	1.85	1	1.85	5.47	0.047 6
	失拟项	1.68	6	0.28	0.54	0.761 3

Table 3

Table 4

Fig.4

Fig.5

Fig.6

Fig.7

Fig.8

Fig.9

Fig.10

Fig.11

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组别	板材硬度（HRB）	胶膜厚度/mm	冲压力/kN	失效载荷			能量吸收
组别	板材硬度（HRB）	胶膜厚度/mm	冲压力/kN	试验值/N	模型预测值/N	误差/%	试验值/J	模型预测值/J	误差/%
1	18	0.08	48.5	5 127.272	5 712.8	11.42	5.431 4	5.235 6	3.6
2	32	0.10	56.2	6 067.037	6 171.9	1.73	6.315 9	5.812 9	7.9

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Aluminum alloy clinch-bonding with hot melt adhesive film and joint failure analysis

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