Abstract
Joining by plastic deformation, also called joining by forming techniques, has been developed as a powerful tool for joining a broad range of similar and dissimilar materials in an environmentally friendly manner. Generally, the joining by forming techniques fall into two distinctive categories, namely mechanical joining and solid state welding. In this paper, different methods of joining by forming are studied from processing and manufacturing points of view. The article is arranged in three parts. Mechanical joining processes will be discussed in this part A. Various processes in this category have been addressed individually. Principles of the processing, applicable materials, process variants, joint mechanical behavior including static and dynamic performance, and various optimization techniques including experimental, numerical, and analytical approaches are the fields of concentration in this study.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Baldan A (2004) Adhesively-bonded joints in metallic alloys, polymers and composite materials: mechanical and environmental durability performance. J Mater Sci 39:4729–4797
Hart-Smith LJ (1999) A peel-type durability test coupon to assess interfaces in bonded, co-bonded, and co-cured composite structures. Int J Adhes Adhes 19(2–3):181–191
Crumple zones are well designed. [Online]. Available: http://www.suburbanautobody.com/Blog/entryid/15
Lambiase F, Ko DC (2016) Feasibility of mechanical clinching for joining aluminum AA6082-T6 and carbon fiber reinforced polymer sheets. Mater Des 107:341–352
Homberg W, Marré M, Beerwald C, Kleiner M (2006) Joining by forming of lightweight frame structures. Adv Mater Res 10:89–100
Mori K, Bay N, Fratini L, Micari F, Tekkaya AE (2013) Joining by plastic deformation. CIRP Ann Manuf Technol 62(2):673–694
Groche P, Wohletz S, Brenneis M, Pabst C, Resch F (2014) Joining by forming—a review on joint mechanisms , applications and future trends. J Mater Process Technol 214(10):1972–1994
Groche P, Turk M (2011) Smart structures assembly through incremental forming. CIRP Ann Manuf Technol 60:21–24
Mori K, Abe Y (2018) A review on mechanical joining of aluminium and high strength steel sheets by plastic deformation. Int J Light Mater Manuf 1(1):1–11
Godwin EW, Matthews FL (1980) A review of the strength of joints in fibre-reinforced plastics: Part 1. Mechanically fastened joints. Composites 11:155–160
Hart-Smith LJ (1980) Mechanically fastened joints for advanced composites—phenomenological considerations and simple analyses. Fibrous Composites in Structural Design 543–574
Kelly G (2004) Joining of carbon fibre reinforced plastics for automotive applications. Royal Institute of Technology Stockholm, Sweden
International Impulse Forming Group (2016) Joining by high velocity forming. [Online]. Available: http://i2fg.org/impulse-forming/joining-by-high-velocity-forming/
Salamati M, Soltanpour M, Fazli A and Zajkani A (2017) Parametric study on the electromagnetic force-fit joining of carbon fiber reinforced plastic and aluminum tubes. Procedia Eng 12th Int Conf Technol Plast ICTP 2017 207:986–991
Park YB, Kim HY, Oh SI (2005) Design of axial/torque joint made by electromagnetic forming. Thin-Walled Struct 43:826–844
Lambiase F, Di Ilio A (2013) Optimization of the clinching tools by means of integrated FE modeling and artificial intelligence techniques. Procedia CIRP 12:163–168
Lambiase F, Di Ilio A, Paoletti A (2015) Joining aluminium alloys with reduced ductility by mechanical clinching. Int J Adv Manuf Technol 77:1295–1304
Carboni M, Beretta S, Monno M (2006) Fatigue behaviour of tensile-shear loaded clinched joints. Eng Fract Mech 73:178–190
Pedreschi RF, Sinha BP (2008) An experimental study of cold formed steel trusses using mechanical clinching. Constr Build Mater 22:921–931
Abe Y, Mori K, Kato T (2012) Joining of high strength steel and aluminium alloy sheets by mechanical clinching with dies for control of metal flow. J Mater Process Technol 212:884–889
Su ZM, Lin PC, Lai WJ, Pan J (2015) Fatigue analyses of self-piercing rivets and clinch joints in lap-shear specimens of aluminum sheets. Int J Fatigue 72:53–65
Lambiase F, Di Ilio A (2015) Mechanical clinching of metal-polymer joints. J Mater Process Technol 215:12–19
Hamel V, Roelandt JM, Gacel JN, Schmit F (2000) Finite element modeling of clinch forming with automatic remeshing. Comput Struct 77:185–200
Neugebauer R, Kraus C, Dietrich S (2008) Advances in mechanical joining of magnesium. CIRP Ann Manuf Technol 57:283–286
Lambiase F (2013) Influence of process parameters in mechanical clinching with extensible dies. Int J Adv Manuf Technol 66:2123–2131
Lambiase F (2015) Joinability of different thermoplastic polymers with aluminium AA6082 sheets by mechanical clinching. Int J Adv Manuf Technol 80:1995–2006
Mucha J (2011) The analysis of rectangular clinching joint in the shearing test. Maint Reliab 3:45–50
Abe Y, Saito T, Nakagawa K, Mori K (2018) Rectangular shear clinching for joining of ultra-high strength steel sheets. Procedia Manuf 15:1354–1359
Lambiase F, Durante M, Di Ilio A (2016) Fast joining of aluminum sheets with glass fiber reinforced polymer (GFRP) by mechanical clinching. J Mater Process Technol 236:241–251
Mucha J (2011) The analysis of lock forming mechanism in the clinching joint. Mater Des 32:4943–4954
Lambiase F (2015) Mechanical behaviour of polymer-metal hybrid joints produced by clinching using different tools. Mater Des 87:606–618
Lambiase F, Di Ilio A (2014) An experimental study on clinched joints realized with different dies. Thin-Walled Struct 85:71–80
Ismail MIS, Buang AS (2018) Precision joining of steel-aluminum hybrid structure by clinching process. J Adv Manuf Technol 12(1):25–36
Zajkani A and Salamati M (2016) Numerical and experimental investigation of joining aluminium and carbon fiber reinforced composites by electromagnetic forming process. In: Proceedings of 7th International Conference on High Speed Forming—ICHSF-2016, pp 59–68
Krztoń H, Mucha J, Witkowski W (2016) The application of laboratory X-ray micro-diffraction to study the effects of clinching process in steel sheets. Acta Phys Pol A 130(4):985–987
He X, Zhang Y, Xing B, Gu F, Ball A (2015) Mechanical properties of extensible die clinched joints in titanium sheet materials. Mater Des 71:26–35
Neugebauer R, Mauermann R, Dietrich S, Kraus C (2007) A new technology for the joining by forming of magnesium alloys. Prod Eng Res Dev 1:65–70
Xing B, He X, Wang Y, Yang H, Deng C (2015) Study of mechanical properties for copper alloy H62 sheets joined by self-piercing riveting and clinching. J Mater Process Technol 216:28–36
Lee CJ, Kim JY, Lee SK, Ko DC, Kim BM (2010) Parametric study on mechanical clinching process for joining aluminum alloy and high-strength steel sheets. J Mech Sci Technol 24:123–126
Varis JP (2003) The suitability of clinching as a joining method for high-strength structural steel. J Mater Process Technol 132:242–249
Abe Y, Kishimoto M, Kato T, Mori K (2009) Joining of hot-dip coated steel sheets by mechanical clinching. Int J Mater Form 2(1):291–294
Zhou Y, Lan F, and Chen J (2010) Influence of tooling geometric parameters on clinching joint properties for steel-aluminum hybrid car-body structures. In: Computer Science and Information Technology (ICCSIT), 2010 3rd IEEE International Conference on, Volume 5, pp 441–445
Kaščák L, Spišák E, Kubik R, Mucha J (2016) FEM analysis of clinching tool load in a joint of dual-phase steels. Strength Mater. 48(4):533–539
Kaščák L, Mucha J, Spišák E, Kubik R (2017) Wear study of mechanical clinching dies during joining of advanced high-strength steel sheets. Strength Mater 49(5):726–737
Lüder S, Härtel S, Binotsch C, Awiszus B (2014) Influence of the moisture content on flat-clinch connection of wood materials and aluminium. J Mater Process Technol 214:2069–2074
Lee CJ, Lee JM, Ryu HY, Lee KH, Kim BM, Ko DC (2014) Design of hole-clinching process for joining of dissimilar materials—Al6061-T4 alloy with DP780 steel, hot-pressed 22MnB5 steel , and carbon fiber reinforced plastic. J Mater Process Technol 214:2169–2178
Lee SH, Lee CJ, Lee KH, Lee JM, Kim BM, Ko DC (2014) Influence of tool shape on hole clinching for carbon fiber-reinforced plastic and SPRC440. Adv Mech Eng 6:1–12
Busse S, Merklein M, Roll K, Ruther M, Zürn M (2010) Development of a mechanical joining process for automotive body-in-white production. Int J Mater Form 3(1):1059–1062
Meschut G, Matzke M, Hoerhold R, Olfermann T (2014) Hybrid technologies for joining ultra-high-strength boron steels with aluminum alloys for lightweight car body structures. Procedia CIRP 23:19–23
Han D, Hörhold R, Wiesenmayer S, Merklein M, Meschut G (2018) Investigation of the influence of tool-sided parameters on deformation and occurring tool loads in shear-clinching processes. Procedia Manuf 15:1346–1353
Hörhold R, Müller M, Merklein M, Meschut G (2016) Mechanical properties of an innovative shear-clinching technology for ultra-high-strength steel and aluminium in lightweight car body structures. Weld World 60(3):613–620
Abibe AB, Amancio-Filho ST, Dos Santos JF, Hage E (2011) Development and analysis of a new joining method for polymer-metal hybrid structures. J Thermoplast Compos Mater 24:233–249
Abibe AB, Amancio-filho ST, Santos JF, Hage E Jr (2013) Mechanical and failure behaviour of hybrid polymer-metal staked joints. Mater Des 46:338–347
Neugebauer R, Mauermann R, Grützner R (2008) Hydrojoining. Int J Mater Form 1(1):1303–1306
Chen C, Zhao S, Cui M, Han X, Fan S (2016) Mechanical properties of the two-steps clinched joint with a clinch-rivet. J Mater Process Technol 237:361–370
Mucha J, Witkowski W (2014) The clinching joints strength analysis in the aspects of changes in the forming technology and load conditions. Thin Walled Struct 82:55–66
Kaščák L, Spišák E, Mucha J (2013) Clinchrivet as an alternative method to resistance spot welding. Acta Mech Autom 7(2):79–82
Mucha J, Kaščák L and Spišák E (2013) The experimental analysis of forming and strength of clinch riveting sheet metal joint made of different materials. Adv Mech Eng 5:1–11
Zhang Y, Shan H, Li Y, Guo J, Luo Z, Ma CY (2017) Joining aluminum alloy 5052 sheets via novel hybrid resistance spot clinching process. Mater Des 118:36–43
Zhang Y, Wang C, Shan H, Li Y, Luo Z (2018) High-toughness joining of aluminum alloy 5754 and DQSK steel using hybrid clinching–welding process. J Mater Process Technol 259:33–44
Wang X, Li C, Ma Y, Shen Z, Sun X, Sha C, Gao S, Li L, Liu H (2016) An experimental study on micro clinching of metal foils with cutting by laser shock forming. Materials (Basel) 9(7):571
Wang X, Li X, Li C, Shen Z, Ma Y, Liu H (2018) Laser shock micro clinching of Al/Cu. J Mater Process Technol 258(April):200–210
Osten J, Söllig P, Reich M, Kalich J, Füssel U, Kessler O (2014) Softening of high-strength steel for laser assisted clinching. Adv Mater Res 966–967:617–627
Lambiase F (2015) Clinch joining of heat-treatable aluminum AA6082-T6 alloy under warm conditions. J Mater Process Technol 225:421–432
Zhou H, Cui H, Qin QH (2018) Influence of ultrasonic vibration on the plasticity of metals during compression process. J Mater Process Technol 251(May 2018):146–159
Heßeln F, Wanner MC (2014) Ultrasonic assisted clinching of aluminium alloy sheets. Adv Mater Res 966–967:641–650
Mizushima D, Sato T, Murakami H, Ohtake N (2011) Stirring phenomenon of aluminum sheets by ultrasonic vibrations and its application to clinching. J Solid Mech Mater Eng 5(12):810–824
Beyer E, Kalich J, Kotter H (2006) Vorrichtung und Verfahren zum formschlussigen Verbinden von Werkstucken. Patent DE102004062896B4
He X (2017) Clinching for sheet materials. Sci Technol Adv Mater 18(1):381–405
Reich M, Osten J, Milkereit B, Kalich J, Füssel U, Kessler O (2014) Short-time heat treatment of press hardened steel for laser assisted clinching. Mater Sci Technol 30(11):1287–1296
Chen LW, Huang JM, Hsu YC (2015) Investigation of the clinching process combines with hot stamping process for high-strength steel sheets. MATEC Web Conf 21
Chen LW, Cai MJ (2018) Development of a hot stamping clinching tool. J Manuf Process 34(June):650–658
Lambiase F, Paoletti A, Di Ilio A (2017) Advances in mechanical clinching: employment of a rotating tool. Procedia Eng 183:200–205
Lambiase F, Paoletti A (2018) Friction-assisted clinching of aluminum and CFRP sheets. J Manuf Process 31:812–822
Lambiase F, Paoletti A (2018) Mechanical behavior of AA5053/polyetheretherketone (PEEK) made by friction assisted joining. Compos Struct 189:70–78
Mota NG, Costa CPA (2005) A comparative study between the sheet joining processes by point TOX and spot welding, In Proceedings of the Annual Congress of the Brazilian Society for Metallurgy and Materials, pp 2733–2741
Mucha J (2011) Joining the car-body sheets using clinching process with various thickness and mechanical property arrangements. Arch Civ Mech Eng XI(1):135–148
He X, Zhao L, Yang H, Xing B, Wang Y, Deng C, Gu F, Ball A (2014) Investigations of strength and energy absorption of clinched joints. Comput Mater Sci 94:58–65
Lambiase F, Di Ilio A (2016) Damage analysis in mechanical clinching: experimental and numerical study. J Mater Process Technol 230:109–120
Oudjene M, Ben-Ayed L (2008) On the parametrical study of clinch joining of metallic sheets using the Taguchi method. Eng Struct 30:1782–1788
Roux E, Bouchard PO (2013) Kriging metamodel global optimization of clinching joining processes accounting for ductile damage. J Mater Process Technol 213:1038–1047
Wang X, Li X, Shen Z, Ma Y, Liu H (2018) Finite element simulation on investigations, modeling, and multiobjective optimization for clinch joining process design accounting for process parameters and design constraints. Int J Adv Manuf Technol 96(9–12):3481–3501
Kaščák L, Spišák E, Kubik R, Mucha J (2017) Finite element calculation of clinching with rigid die of three steel sheets. Strength Mater 49(4):488–499
De Paula AA, Aguilar MTP, Pertence AEM, Cetlin PR (2007) Finite element simulations of the clinch joining of metallic sheets. J Mater Process Technol 182:352–357
Abe Y, Kato T, Mori K, Nishino S (2014) Mechanical clinching of ultra-high strength steel sheets and strength of joints. J Mater Process Technol 214(10):2112–2118
Oudjene M, Ben-ayed L, Delameziere A, Batoz JL (2008) Shape optimization of clinching tools using the response surface methodology with moving least-square. J Mater Process Technol 209:289–296
Lee CJ, Kim JY, Lee SK, Ko DC, Kim BM (2010) Design of mechanical clinching tools for joining of aluminium alloy sheets. Mater Des 31:1854–1861
Ferreira SLC, Bruns RE, Ferreira HS, Matos GD, David JM, Brand GC, Silva EGP, Reis PS, Souza AS, Santos WNL (2007) Box-Behnken design: an alternative for the optimization of analytical methods. Anal Chim Acta 597:179–186
Dean A, Sahraee S, Reinoso J, Rolfes R (2016) Finite deformation model for short fibre reinforced composites: application to hybrid metal-composite clinching joints. Compos Struct 151:162–171
Han L, Chrysanthou A (2008) Evaluation of quality and behaviour of self-piercing riveted aluminium to high strength low alloy sheets with different surface coatings. Mater Des 29:458–468
Abe Y, Kato T, Mori K (2009) Self-piercing riveting of high tensile strength steel and aluminium alloy sheets using conventional rivet and die. J Mater Process Technol 209:3914–3922
He X, Pearson I, Young K (2008) Self-pierce riveting for sheet materials: state of the art. J Mater Process Technol 199:27–36
Pickin CG, Young K, Tuersley I (2007) Joining of lightweight sandwich sheets to aluminium using self-pierce riveting. Mater Des 28:2361–2365
Han L, Chrysanthou A, Young KW (2007) Mechanical behaviour of self-piercing riveted multi-layer joints under different specimen configurations. Mater Des 28:2024–2033
Ioannou J (2009) Mechanical behavior and corrosion of interstitial-free steel to aluminum alloy self-piercing riveted joints. University of Hertfordshire, Hertfordshire
Voelkner W (2000) Present and future developments of metal forming: selected examples. J Mater Process Technol 106:236–242
Durandet Y, Deam R, Beer A, Song W, Blacket S (2010) Laser assisted self-pierce riveting of AZ31 magnesium alloy strips. Mater Des 31:S13–S16
Han L, Chrysanthou A, O’Sullivan JM (2006) Fretting behaviour of self-piercing riveted aluminium alloy joints under different interfacial conditions. Mater Des 27:200–208
Barnes TA, Pashby IR (2000) Joining techniques for aluminium spaceframes used in automobiles. Part II—adhesive bonding and mechanical fasteners. J Mater Process Technol 99:72–79
Abe Y, Kato T, Mori K (2006) Joinability of aluminium alloy and mild steel sheets by self piercing rivet. J Mater Process Technol 177:417–421
Fratini L, Ruisi VF (2009) Self-piercing riveting for aluminium alloys-composites hybrid joints. Int J Adv Manuf Technol 43:61–66
Hoang NH, Porcaro R, Langseth M, Hanssen AG (2010) Self-piercing riveting connections using aluminium rivets. Int J Solids Struct 47(3–4):427–439
Abe Y, Kato T, Mori K (2008) Self-pierce riveting of three high strength steel and aluminium alloy sheets. Int J Mater Form 1(1):1271–1274
Meschut G, Gude M, Augenthaler F, Geske V (2014) Evaluation of damage to carbon-fibre composites induced by self-pierce riveting. Procedia CIRP 18:186–191
Ueda M, Miyake S, Hasegawa H, Hirano Y (2012) Instantaneous mechanical fastening of quasi-isotropic CFRP laminates by a self-piercing rivet. Compos Struct 94(11):3388–3393
Di Franco G, Fratini L, Pasta A (2012) Influence of the distance between rivets in self-piercing riveting bonded joints made of carbon fiber panels and AA2024 blanks. Mater Des 35:342–349
Briskham P, Blundell N, Han L, Hewitt R, Young K, Boomer D (2006) Comparison of self-pierce riveting , resistance spot welding and spot friction joining for aluminium automotive sheet. SAE Technical Paper 2006-01-0774
Han L, Thornton M, Shergold M (2010) A comparative study between self-piercing riveting and resistance spot welding of aluminium sheets for the automotive industry. Mater Des 31(3):1457–1467
Lennon R, Pedreschi R, Sinha BP (1999) Comparative study of some mechanical connections in cold formed steel. Constr Build Mater 13:109–116
Mori K, Abe Y, Kato T (2012) Mechanism of superiority of fatigue strength for aluminium alloy sheets joined by mechanical clinching and self-pierce riveting. J Mater Process Technol 212:1900–1905
Mucha J, Witkowski W (2015) Mechanical behavior and failure of riveting joints in tensile and shear tests. Strength Mater 47(5):755–769
Mucha J (2014) The numerical analysis of the effect of the joining process parameters on self-piercing riveting using the solid rivet. Arch Civ Mech Eng 14(3):444–454
Mucha J (2015) The failure mechanics analysis of the solid self-piercing riveting joints. Eng Fail Anal 47:77–88
Sun X, Stephens EV, Khaleel MA (2007) Fatigue behaviors of self-piercing rivets joining similar and dissimilar sheet metals. Int J Fatigue 29:370–386
Li B, Fatemi A (2006) An experimental investigation of deformation and fatigue behavior of coach peel riveted joints. Int J Fatigue 28:9–18
Fu M, Mallick PK (2003) Fatigue of self-piercing riveted joints in aluminum alloy 6111. Int J Fatigue 25:183–189
Chen YK, Han L, Chrysanthou A, O’Sullivan JM (2003) Fretting wear in self-piercing riveted aluminium alloy sheet. Wear 255:1463–1470
Zhang X, He X, Xing B, Zhao L, Lu Y, Gu F, Ball A (2016) Influence of heat treatment on fatigue performances for self-piercing riveting similar and dissimilar titanium, aluminium and copper alloys. Mater Des 97:108–117
Lee MH, Kim HY, Oh SI (2006) Crushing test of double hat-shaped members of dissimilar materials with adhesively bonded and self-piercing riveted joining methods. Thin-Walled Struct 44:381–386
Porcaro R, Langseth M, Hanssen AG, Zhao H, Weyer S, Hooputra H (2008) Crashworthiness of self-piercing riveted connections. Int J Impact Eng 35:1251–1266
Han L, Young KW, Chrysanthou A, O’Sullivan JM (2006) The effect of pre-straining on the mechanical behaviour of self-piercing riveted aluminium alloy sheets. Mater Des 27:1108–1113
Johnson P, Cullen JD, Sharples L, Shaw A, Al-shamma’a AI (2009) Online visual measurement of self-pierce riveting systems to help determine the quality of the mechanical interlock. Measurement 42(5):661–667
Xie Z, Yan W, Yu C, Mu T, Song L (2018) Experimental investigation of cold-formed steel shear walls with self-piercing riveted connections. Thin-Walled Struct 131(May):1–15
He X, Gu F, Ball A (2012) Recent development in finite element analysis of self-piercing riveted joints. Int J Adv Manuf Technol 58:643–649
Mori K, Kato T, Abe Y, Ravshanbek Y (2006) Plastic joining of ultra high strength steel and aluminium alloy sheets by self piercing rivet. Ann CIRP 55(1):283–286
Mucha J (2011) A study of quality parameters and behaviour of self-piercing riveted aluminium sheets with different joining conditions. J Mech Eng 57(4):323–333
Porcaro R, Hanssen AG, Langseth M, Aalberg A (2006) Self-piercing riveting process: an experimental and numerical investigation. J Mater Process Technol 171:10–20
Cai W, Wang PC, Yang W (2005) Assembly dimensional prediction for self-piercing riveted aluminum panels. Int J Mach Tools Manuf 45:695–704
Qu SG, Deng WJ (2008) Finite element simulation of the self-piercing riveting process. In: Proceedings of International Mechanical Engineering Congress and Exposition, pp 1–7
Porcaro R, Hanssen AG, Langseth M, Aalberg A (2006) The behaviour of a self-piercing riveted connection under quasi-static loading conditions. Int J Solids Struct 43:5110–5131
Westerberg C (2002) Finite element simulation of crash testing of self-piercing rivet joints, peel specimen. MS Dissertation. Lund University, Sweden
Carandente M, Dashwood RJ, Masters IG, Han L (2016) Improvements in numerical simulation of the SPR process using a thermo-mechanical finite element analysis. J Mater Process Technol 236:148–161
Li Y, Wei Y, Wang Z, Li Z (2013) Friction self-pierce riveting of aluminum alloy AA6061-T6 to magnesium alloy AZ31B. J Manuf Sci Eng 135(6):061007
Ma Z, Li Y, Hu Y, Lou W, Lin M (2016) Modeling of friction self-piercing riveting of aluminum to magnesium. J Manuf Sci Eng 138:061007
Liu X, Lim YC, Li Y, Tang W, Ma Y, Feng Z, Ni J (2016) Effects of process parameters on friction self-piercing riveting of dissimilar materials. J Mater Process Technol 237:19–30
Ma Y, Xian X, Lou M, Li Y, Lin Z (2017) Friction self-piercing riveting (F-SPR) of dissimilar materials. Procedia Eng 207:950–955
Mucha J (2013) The effect of material properties and joining process parameters on behavior of self-pierce riveting joints made with the solid rivet. Mater Des 52:932–946
Hahn O, Meschut G, Bergau M, Matzke M (2014) Self-pierce riveting and hybrid joining of boron steels in multi-material and multi-sheet joints. Procedia CIRP 18:192–196
Li Y, Wei Z, Wang Z, Li Y (2013) Friction self-piercing riveting of aluminum alloy AA6061-T6 to magnesium alloy AZ31B. J Manuf Sci Eng 135(6):7. 061007
Livatyali H, Muderrisoglu A, Ahmetoglu MA, Akgerman N, Kinzel GL, Altan T (2000) Improvement of hem quality by optimizing-anging and pre-hemming operations using computer aided die design. J Mater Process Technol 98:41–52
Svensson M, Mattiasson K (2002) Three-dimensional simulation of hemming with the explicit FE-method. J Mater Process Technol 128:142–154
Zhang G, Hao H, Wu X, Hu SJ (2000) An experimental investigation of curved surface-straight edge hemming. J Manuf Process 2(4):241–246
Shang J, Wilkerson L, Hatkevich S (2011) Hemming of aluminum alloy sheets using electromagnetic forming. J Mater Eng Perform 20:1370–1377
Zhang G, Hu SJ, Wu X (2003) Numerical analysis and optimization of hemming processes. J Manuf Process 5(1):87–96
Altan AE, Tekkaya T (2012) Sheet metal forming, processes and applications. ASM International, Materials Park, Ohio
Livatyali H, Larris SJ (2004) Experimental investigation on forming defects in flat surface-convex edge hemming: roll, recoil and warp. J Mater Process Technol 153–154:913–919
Wanintradul C, Golovashchenko SF, Gillard AJ, Smith LM (2014) Hemming process with counteraction force to prevent creepage. J Manuf Process 16(3):379–390
Svensson M and Mattiasson K (2000) Simulation of hemming of automotive body components with the explicit FE-method. In: European Congress on Computational Methods in Applied Sciences and Engineering, pp 1–12
Le Maoût N, Thuillier S, Manach PY (2010) Drawing , flanging and hemming of metallic thin sheets: a multi-step process. Mater Des 31:2725–2736
Huang YM (2007) An elasto-plastic finite element analysis of the sheet metal stretch flanging process. Int J Adv Manuf Technol 34:641–648
Hamedon Z, Mori K, Abe Y (2014) Hemming for joining high strength steel sheets. Procedia Eng 81:2074–2079
Jimbert P, Eguia I, Perez I, Gutierrez MA, Hurtado I (2011) Analysis and comparative study of factors affecting quality in the hemming of 6016T4AA performed by means of electromagnetic forming and process characterization. J Mater Process Technol 211:916–924
Muderrisoglu A, Murata M, Ahmetoglu MA, Kinzel G, Altan T (1996) Bending, flanging, and hemming of aluminum sheet-an experimental study. J Mater Process Technol 59:10–17
Lin G, Iyer K, Hu SJ, Cai W, Marin SP (2005) A computational design-of-experiments study of hemming processes for automotive aluminium alloys. J Eng Manuf 219:711–722
Golovashchenko SF (2005) Sharp flanging and flat hemming of aluminum exterior body panels. J Mater Eng Perform 14:508–515
Hu X, Zhao Y, Huang S, Li S, Lin Z (2012) Numerical analysis of the roller hemming process. Int J Adv Manuf Technol 62:543–550
Hu X, Lin ZQ, Li SH, Zhao YX (2010) Fracture limit prediction for roller hemming of aluminum alloy sheet. Mater Des 31:1410–1416
Thuillier S, Le Maout N, Manach PY, Debois D (2008) Numerical simulation of the roll hemming process. J Mater Process Technol 198:226–233
Levinson A, Mishra RK, Doherty RD, Surya RK (2012) Microstructure evolution during roller hemming of AZ31B magnesium sheet. Metall Mater Trans A 43A:3824–3833
Carsley J, Kim S (2007) Warm hemming of magnesium sheet. J Mater Eng Perform 16:331–338
Hagedorn M, Weinert K (2004) Manufacturing of composite workpieces with rolling tools. J Mater Process Technol 153–154:323–329
Przybylski W, Wojciechowski J, Klaus A, Marré M, Kleiner M (2008) Manufacturing of resistant joints by rolling for light tubular structures. Int J Adv Manuf Technol 35:924–934
Merklein M, Geiger M, Celeghini M (2005) Combined tube and double sheet hydroforming for the manufacturing of complex parts. CIRP Ann Manuf Technol 54(1):199–204
Marre M, Ruhstorfer M, Tekkayya AE, Zaeh MF (2009) Manufacturing of light-weight frame structures by innovative joining by forming processes. Int J Mater Form 2(1):307–310
Marre M, Gies S, Maevus F, Tekkaya AE (2010) Joining of lightweight frame structures by die-less hydroforming. Int J Mater Form 3(1):1031–1034
Groche P, Tibari K (2006) Fundamentals of angular joining by means of hydroforming. Ann CIRP 55(1):259–262
Wang X, Li P, Wang R (2005) Study on hydro-forming technology of manufacturing bimetallic CRA-lined pipe. Int J Mach Tools Manuf 45:373–378
Henrard C, Habraken AM, Szekeres A, Duflou JR, He S, Van Bael A, Van Houtte P (2005) Comparison of FEM simulations for the incremental forming process. Adv Mater Res 6–8:533–542
Groche P, Fritsche D, Tekkaya AE, Allwood JM, Hirt G, Neugebauer R (2007) Incremental bulk metal forming. Ann CIRP 56(2):635–656
Mohebbi MS, Akbarzadeh A (2010) A novel spin-bonding process for manufacturing multilayered clad tubes. J Mater Process Technol 210:510–517
Turk M and Groche P (2010) Integration of adaptive components by incremental forming processes. In: SPIE 7643, Active and Passive Smart Structures and Integrated Systems 2010, 76431I
Zhang Q, Jin K, Mu D (2014) Tube/tube joining technology by using rotary swaging forming method. J Mater Process Technol 214(10):2085–2094
Cho JR, Song JI (2007) Swaging process of power steering hose: its finite element analysis considering the stress relaxation. J Mater Process Technol 187–188:497–501
Cho JR, Song JI, Noh KT, Jeon DH (2005) Nonlinear finite element analysis of swaging process for automobile power steering hose. J Mater Process Technol 170:50–57
Shirgaokar M, Cho H, Ngaile G, Altan T, Yu JH, Balconi J, Rentfrow R, Worrell WJ (2004) Optimization of mechanical crimping to assemble tubular components. J Mater Process Technol 146:35–43
Pavloušková Z, Klakurková L, Man O, Švejcar J (2015) Assessment of the cause of cracking of hydraulic hose clamps. Eng Fail Anal 56:14–19
Shirgaokar M, Ngaile G, Altan T, Yu JH, Balconi J, Rentfrow R, Worrell WJ (2004) Hydraulic crimping: application to the assembly of tubular components. J Mater Process Technol 146:44–51
Correia JPM, Siddiqui MA, Ahzi S, Belouettar S, Davies R (2008) A simple model to simulate electromagnetic sheet free bulging process. Int J Mech Sci 50(10–11):1466–1475
Harvey GW and Brower DF (1958) Metal forming device and method. 2976907
Psyk V, Risch D, Kinsey BL, Tekkaya AE, Kleiner M (2011) Electromagnetic forming—a review. J Mater Process Technol 211(5):787–829
Weddeling C, Walter V, Haupt P, Tekkaya AE, Schulze V, André K (2015) Joining zone design for electromagnetically crimped connections. J Mater Process Technol 225:240–261
Eguia I, Zhang P, Daehn GS (2004) Improved crimp-joining of aluminum tubes onto mandrels with undulating surfaces. In: Proceedings of 1st International Conference on High Speed Forming - ICHSF2004, pp 161–170
Hwang WS, Kim NH, Sohn HS, Leeb JS (1992) Electromagnetic joining of aluminum tubes on polyurethane cores. J Mater Process Technol 34:341–348
Kleiner M, Marré M, Beerwald C, Homberg W, Löhe D, Barreiro P, Schulze V (2006) Investigation of force-fit joints produced by electromagnetic tube compression. Ann Ger Acad Soc Prod Eng WGP XIII:227–230
Barreiro P, Schulze V, Löhe D, Marré M, Beerwald C, Homberg W, Kleiner M (2006) Strength of tubular joints made by electromagnetic compression at quasi-static and cyclic loading. In: Proceedings of 2nd International Conference on High Speed Forming-ICHSF-2006, pp 107–116
Bühler H, von Finckenstein E (1968) Fügen durch magnetumformung. Werkstatt und Betr 101(4):209–215
Weddeling AE, Woodward C, Marré ST, Nellesen M, Psyk J, Tekkaya V and Tillman W (2010) Development of design principles for form-fit joints in lightweight frame structures. In: Proceedings of the 4th International Conference on High Speed Forming-CHSF2010, pp 137–148
Weddeling C, Woodward S, Nellesen J, Psyk V, Marré M, Tekkaya AE, Daehn GS, Tillmann W (2010) Development of design principles for form-fit joints in lightweight frame structures. In: Proceedings of 4th International Conference on High Speed Forming-ICHSF-2010, pp 137–148
Buhler E, von Finckenstein H (1971) Bemessung von Sickenverbindungen fur ein Fugen durch Magnetumformung. Werkstatt und Betr 104:45–51
Weddeling C, Woodward ST, Marré M, Nellesen J, Psyk V, Tekkaya AE, Tillmann W (2011) Influence of groove characteristics on strength of form-fit joints. J Mater Process Technol 211:925–935
Golovashchenko S (2001) Methodology of design of pulsed electromagnetic joining of tubes. In: Proceedings of the 2nd Global Symposium on Innovation in Material Processing and Manufacturing: Sheet Materials. TMS Annual Meeting, New Orleans
Hammers T, Marré M, Rautenberg J, Barreiro P, Schulze V, Löhe D, Brosius A, Tekkaya AE (2008) Influence of Mandrel’s surface on the mechanical properties of joints produced by electromagnetic. In: Proceedings of 3rd International Conference on High Speed Forming-ICHSF2008, pp 245–256
Jimbert G, Perez P, Eguia I, Daehn I (2007) Straight hemming on aluminum sheet panels using the electromagnetic forming technology: first approach. Key Eng Mater 344:365–372
Jimbert P, Eguia I, Gutierrez MA, Gonzalez B, Daehn GS, Zhang Y, Anderson R, Sundberg H, Olsson SO, Brännström P (2008) Flanging and hemming of auto body panels using the electro magnetic forming technology. In: Proceedings of 3rd International Conference on High Speed Forming-ICHSF2008, pp 163–172
Deng JH, Tang C, Fu MW, Zhan YR (2014) Effect of discharge voltage on the deformation of Ti grade 1 rivet in electromagnetic riveting. Mater Sci Eng A 591:26–32
Oliveira DA, Worswick MJ, Finn M, Newman D (2005) Electromagnetic forming of aluminum alloy sheet: free-form and cavity fill experiments and model. 170(1–2):350–362
Stiemer H, Unger M, Svendsen J, Blum B (2006) Algorithmic formulation and numerical implementation of coupled electromagnetic-inelastic continuum models for electromagnetic metal forming. Int J Numer Methods Eng 68:1301–1328
Uhlmann D, Jurgasch E (2004) New impulses in the forming of magnesium sheet metals. In: Proceedings of the 1st International Conference on High speed Forming—ICHSF 2004, pp 229–241
Imbert JM, Worswick MJ, Golovashchenko S (2006) Contributing factors to the increased formability observed in electromagnetically formed aluminum alloy sheet. In: Proceedings of 2nd International Conference on High Speed Forming-ICHSF-2006, pp 3–12
Zohoor M, Ghorbani B (2014) Analytical and numerical investigation of significant parameters on strength of electromagnetically assembled aluminum tube joints. Journal of Modern Processes in Manufacturing and Production 3(1):35–46
Tekkaya A, Homberg AE, Brosius W (2015) 60 excellent inventions in metal forming. Springer Vieweg, Berlin
Dörr F, Funk M, Liewald M, Binz H, Köstlmeier R (2014) Influence of internal hub profile on joining process of shaft-hub- connection by lateral extrusion. Procedia Eng 81(October):1988–1993
Danesh Manesh H, Mashreghi A, Ehteman Haghighi S, Khajeh A (2009) Investigation of cold pressure welding of aluminum powder to internal surface of aluminum tube. Mater Des 30(3):723–726
Huang Z, Sugiyama S, Yanagimoto J (2013) Hybrid joining process for carbon fiber reinforced thermosetting plastic and metallic thin sheets by chemical bonding and plastic deformation. J Mater Process Technol 213(11):1864–1874
Yanagimoto J, Ikeuchi K (2012) Sheet forming process of carbon fiber reinforced plastics for lightweight parts. CIRP Ann Manuf Technol 61(1):247–250
Alves LM, Dias EJ, Martins PAF (2011) Joining sheet panels to thin-walled tubular profiles by tube end forming. J Clean Prod 19(6–7):712–719
Alves LM, Martins PAF (2013) Single-stroke mechanical joining of sheet panels to tubular profiles. J Manuf Process 15(1):151–157
Pragana JP, Silva CM, Bragança IM, Alves L, Martins PA (2018) A new joining by forming process to produce lap joints in metal sheets. CIRP Ann Manuf Technol 67(1):301–304
Chrysanthou A, Sun X (2014) Self-piercing riveting: properties, processes, and applications. Woodhead Publishing, Cambridge
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Salamati, M., Soltanpour, M., Fazli, A. et al. Processing and tooling considerations in joining by forming technologies; part A—mechanical joining. Int J Adv Manuf Technol 101, 261–315 (2019). https://doi.org/10.1007/s00170-018-2823-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2823-y