Investigation on metal-CFRP-metal sandwich joint using mechanical clinching process

Abstract

Recently the automobile sector has been moving towards lightweight components for fuel saving and economic operation. The use of carbon fibre-reinforced plastic (CFRP) has increased nowadays due to its lightweight, high strength-to-weight ratio and durability. Mechanical clinching is a process of joining two or more materials by applying pressure by the tool and joint form by interlock creation. This study investigates the joining process of AA 1050-CFRP-AA 1050 sheets in sandwich structure utilizing hole clinching process, joining of sandwich carbon fibre with mild steel sheets using clinching assisted resistance spot welding process and comparison of clinching after spot welding as well as spot welding after clinching . The mechanical strength of the joint was investigated by lap shear and peel tests followed by cross-section analysis. Numerical analysis was performed using ABAQUS software to optimize the size of hole in CFRP, to understand the flow of material in the extensible die and its comparison with experiment result.