There is currently a growing trend towards the development of mechanical joining processes, which has been created by the increase in intelligent lightweight construction with its tendency to combine different materials. This kind of joining technology is characterized by a forming process that involves the mechanical interlocking of materials. For this purpose, the flow of the materials and the joining element is influenced during the joining process in such a way that form and force closure between the combined materials or the additional joining element are achieved. Mechanical joining is the most economical way to manufacture multi-material products.
The trend towards intelligent lightweight construction means that every element of a product must be made of the best materials in terms of function, durability, production and cost. As a result, multi-material composition is increasingly common. The assembly of multi-material elements is the biggest challenge in multi-material design and the biggest driver of costs, and therefore provides the most opportunities for innovation.
To exploit the potential of lightweight construction for a more efficient element design, many industries, especially the automotive and aerospace industries, increasingly use fiber-reinforced plastics, aluminum, cast materials, high strength steels, and metal foams. To safely combine these different materials and form so-called multi-material modules, intensive work on the development of new joining methods and the optimization of existing mechanical joining technologies is currently underway.
Process parameters which must be considered to help adjust the joining technology to the materials, their thicknesses, arrangement, and accessibility include:
Multi-point inspections, meaning interdependency between joining points
Sequential arrangement to minimize assembly distortion
The module Mechanical Joining was specifically designed for the simulation of mechanical joining processes. It allows for the numerical computation of technologies primarily based on joining-based forming. Therefore, various riveting procedures, such as punch riveting, self-piercing riveting or blind riveting, can be analyzed. It is also possible to simulate the connection formation in diverse joining by shearing and upsetting or clinching technologies with a fixed or an opening die. Furthermore, special effects such as high joining speed (e.g., when setting bolts) or a high momentum (e.g. flow-drill screws) can be taken into account. An analysis of adhesives in the joining zone is also feasible.
Simufact Forming Mechanical Joining contains a library of CAD descriptions of your joining tools and elements and automatically calculates the specific connection parameters. Furthermore, this module offers a specially adjusted simulation set-up that ensures solution stability.
When your joining specialists perform robust and high-performance simulations with experimentally validated results, you are able to:
For a functional analysis of Simufact Forming Mechanical Joining, please read our product description.