Stirring Phenomenon of Aluminum Sheets by Ultrasonic Vibrations and Its Application to Clinching

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Clinching is an attractive joining method as one of alternatives meeting the recent significant demand for joining low-weldability materials and dissimilar materials. Because it has many advantages in terms of productivity, cost, recyclability, and no requirements for specific surface conditions of materials. However, application of clinching is restricted by its low joint-strength and the difficulty to join low-ductile materials. Hence, to overcome this problem, we developed a novel clinching process in which ultrasonic vibrations were applied perpendicularly to the materials by the clinching tools. In this paper, the effects of ultrasonic assists on clinching for aluminum sheets in two types of vibration modes were investigated. In one mode, work pieces were located on the maximum-displacement-amplitude position, and in the other mode, materials were located on the maximum-stress-amplitude position. As the results, the application of ultrasonic vibrations in the maximum-displacement-amplitude mode showed no prospective results. Because the applicable vibration amplitudes were restricted by generation of cracks due to the high-cycle bending load. On the other hand, the application of ultrasonic vibrations in the maximum-stress-amplitude mode showed unique vortical flows in the applied material. These vortical flows led to a stirring phenomenon in the material, and the aluminum sheets were unified. Due to the unification by the stirring phenomenon, the cross-tensile strength was increased up to 60 % and the joining pressure was reduced up to 80 %. And a grain refinement effect was also observed. Finally we discussed about the potentials of the stirring phenomenon for joining dissimilar materials and a new grain-size refinement method.

Stirring Phenomenon of Aluminum Sheets by Ultrasonic Vibrations and Its Application to Clinching

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