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Laboratory for material and joining technology (LWF)

Prof. Dr.-Ing. Gerson Meschut

Contact
Publications
Prof. Dr.-Ing. Gerson Meschut

Werkstoff- und Fügetechnik

Head - Professor - Head of institute

Institut für Leichtbau mit Hybridsystemen (ILH)

Committee - Professor - Vorstand ILH

Phone:
+49 5251 60-3031
Fax:
+49 5251 60-3239
Office:
P1.4.11.1
Web:
Visitor:
Pohlweg 47-49
33098 Paderborn

Transregional Collaborative Research Centre 285

Speaker - Professor - Teilprojekte A01, C02, Z

Phone:
+49 5251 60 3031
Fax:
+49 5251 60 3239

Open list in Research Information System

2022

Methodology for the systematic investigation of the hygrothermal-mechanical behavior of a structural epoxy adhesive

S. Sander, G. Meschut, U. Kroll, A. Matzenmiller, International Journal of Adhesion and Adhesives (2022), 103072

DOI


Weight-optimized Battery Housings for Volume Vehicles

T. Schmolke, C. Krüger, D. Merdivan, G. Meschut, ATZ worldwide (2022), 124(1), pp. 66-71

DOI


Methodenentwicklung zur rechnerischen Auslegung geklebter Stahlverbindungen unter Alterungsbeanspruchung im Stahl- und Anlagenbau

S. Sander, D. Teutenberg, G. Meschut, F. Kötz, A. Matzenmiller, Y. Kasper, T. Ummenhofer, in: 22. Kolloquium Gemeinsame Forschung in der Klebtechnik, 2022


Gewichtsoptimierte Batteriegehäuse für Volumenfahrzeuge

T. Schmolke, C. Krüger, D. Merdivan, G. Meschut, ATZ - Automobiltechnische Zeitschrift (2022), 124(1), pp. 80-85

DOI


Metamodellbasierte Prozesskette - Umformen-Schneiden-Spannen-Fügen

P. Heyser, G. Meschut, T. Nehls, C. Scharr, P. Froitzheim, W. Flügge, S. Wiesenmayer, M. Merklein, in: Pressen, Systeme, Prozesse der Zukunft Effizienz + Digitalisierung, Europäische Forschungsgesellschaft für Blechverarbeitung e.V., 2022


Konzeption einer adaptiven Prozesskette für das mechanische Fügen

G. Meschut, P. Heyser, M. Merklein, S. Wiesenmayer, W. Flügge, C. Scharr, T. Nehls, Europäische Forschungsgesellschaft für Blechverarbeitung e.V, 2022


Smart process chain – data analysis in sheet metal processing for joinability prediction

P. Heyser, S. Wiesenmayer, T. Nehls, C. Scharr, W. Flügge, M. Merklein, G. Meschut, in: SMART PRODUCTION 2022: DIGITALIZING AUTOMOTIVE MANUFACTURING, Automotive Circle, 2022


Development of a test method for investigating the leak tightness of hybrid joined battery housing connections

T. Schmolke, D. Teutenberg, G. Meschut, International Journal of Adhesion and Adhesives (2022), 117, 103171

DOI


Directional dependence of the mechanical properties of structural adhesive joints with curing-induced pre-deformations

F. Beule, D. Teutenberg, G. Meschut, Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering (2022), 095440702211001

<jats:p> Owing to the implementation of multi-material construction methods in modern lightweight construction and the associated use of adhesive bonding technology, thermally induced relative displacements of the joining partners occur during the curing process. The resulting extremely complex thermo-chemo-mechanical stresses can influence the properties of the adhesive layers and reduce the load-bearing capacity. In this study, experiments are conducted to examine the influence of process-related thermal relative displacements on the mechanical properties of adhesives. The results show an anisotropy of the mechanical properties of the pre-deformed adhesive layers, depending on the magnitude and direction of the relative displacement. </jats:p>


Stress-based fatigue lifetime prediction of adhesively bonded joints with hyperelastic deformation behavior

S. Çavdar, G. Meschut, in: 45th Annual Meeting of The Adhesion Society, 2022


Methodenentwicklung zur Versagensanalyse aufgrund der Aushärtung vorgeschädigter Klebverbindungen in stahlintensiven Mischbaustrukturen

F. Beule, D. Teutenberg, G. Meschut, T. Aubel, A. Matzenmiller. Methodenentwicklung zur Versagensanalyse aufgrund der Aushärtung vorgeschädigter Klebverbindungen in stahlintensiven Mischbaustrukturen. 2022.


Lebensdauerprognose für Stahlklebverbindungen bei multiaxialer Belastung mit Phasenverschiebung, veränderlicher Mittelspannung und variablen Amplituden

V. Carillo Beber, C. Nagel, B. Mayer, C. Köster, A. Matzenmiller, M. Hecht, J. Baumgartner, T. Melz, K. Tews, S. Çavdar, G. Meschut, in: 22. Kolloquium: Gemeinsame Forschung in der Klebtechnik, 2022


Methodenentwicklung zur numerischen Lebensdauerprognose von hyperelastischen Klebverbindungen infolge zyklischer Beanspruchung mittels bruchmechanischer Ansätze

K. Tews, T. Aubel, D. Teutenberg, G. Meschut, T. Duffe, G. Kullmer, in: 22. Kolloquium: Gemeinsame Forschung in der Klebtechnik, 2022


DigiBody - Digitale Prozesskette zur Abbildung und Optimierung der Fügetechnik im Rohbau

S. Jamei, N. Döller, S. Lossau, F. Beule, M. Al Trjman, T. Aubel, G. Meschut, D. Sommer, S. Facciotto, A. Droste, A. Haufe, M. Helbig, H. Gleich, K. Kose. DigiBody - Digitale Prozesskette zur Abbildung und Optimierung der Fügetechnik im Rohbau . 2022.



Analyse des Versagensverhaltens geklebter Stahl-Verbindungen beim werkstoffschonenden Entfügen in der Karosserieinstandsetzung

N. Chudalla, G. Meschut, A. Bartley, T.M. Wibbeke, in: 22. Kolloquium: Gemeinsame Forschung in der Klebtechnik, 2022


Methodenentwicklung für die Simulation mechanischer Fügeprozesse mit besonderer Berücksichtigung fügespezifischer Reibverhältnisse

M.S. Rossel, G. Meschut, Europäische Forschungsgesellschaft für Blechverarbeitung e.V., 2022, pp. 180



Experimentelle und numerische Untersuchung des Einflusses variabler Betriebstemperaturen auf das Trag- und Versagensverhalten struktureller Klebverbindungen unter Crashbelastung

M. Striewe, G. Meschut, L. Schmelzle, J. Mergheim, G. Possart, P. Steinmann. Experimentelle und numerische Untersuchung des Einflusses variabler Betriebstemperaturen auf das Trag- und Versagensverhalten struktureller Klebverbindungen unter Crashbelastung. 2022.


Fatigue strength of adhesively butt-bonded hollow cylinders under multiaxial loading with constant and variable amplitudes

M. Hecht, J. Baumgartner, K. Tews, S. Çavdar, G. Meschut, Procedia Structural Integrity (2022), 38, pp. 251-259

DOI


Increasing flexibility of self-piercing riveting by reducing tool–geometry combinations using cluster analysis in the application of multi-material design

F. Kappe, L. Schadow, M. Bobbert, G. Meschut, Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications (2022)

DOI


Determining the properties of multi‑range semi‑tubular self‑piercing riveted joints

F. Kappe, S. Wituschek, M. Bobbert, G. Meschut, Production Engineering (2022)

DOI


Increasing the accuracy of clinching process simulations by modeling the friction as a function of local joining process parameters

M.S. Rossel, G. Meschut, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications (2022), 146442072210742

<jats:p> In this study, an innovative friction model is used to improve the quality of clinching process simulations. Consequently, the future over dimensioning can be reduced. Furthermore, the improved prediction quality of the joining process simulation leads to an improvement in the simulation of load-bearing capacity as well. In this way, the entire sampling process can be performed virtually without any experimental investigations. This will contribute to the advancement of lightweight construction in the automotive industry. In this work, the frictional behavior is studied in dependence on the local joining process parameters. As a reference for the numerical investigations, clinch joints by means of a die with fixed geometry are joined. Additionally, a hardness mapping is performed on the microsection of the clinch joints. It shows the local strain hardening, which correlates with the forming degree in the simulation. Based on the occurring contacts and the local joining process parameters in the joining process simulation, the test matrix for the experimental friction tests is defined. The friction tests are carried out on a compression-torsion-tribometer. This type of tribometer is able to apply high interface pressures above the initial yield stress due to the specimen encapsulation. Besides, the pure joining part contact, the contact between the joining part and joining tool can be tested as well. The experimental test setup offers the possibility to evaluate the influences of temperature, relative velocity, interface pressure, and frictional stroke independently. Based on the results of the experimental friction tests, a friction model is created. The resulting friction model is integrated into the numerical joining process simulation via a subroutine. To validate the quality of the new friction modeling, the results of simulations are compared with the experiments in terms of load-stroke diagrams, joint geometry, and hardness mappings on the microsection. </jats:p>


Process-adapted temperature application within a two-stage rivet forming process for high nitrogen steel

C. Kuball, B. Uhe, G. Meschut, M. Merklein, Proceedings of the Institution of Mechanical Engineers Part L-Journal of Materials-Design and Applications (2022), pp. 1-17

DOI


Investigation of the friction conditions of self-pierce rivets by means of a compression-torsion tribometer

M.S. Rossel, G. Meschut, Production Engineering (2022)

Lightweight design is an effective lever for achieving fuel consumption and emission-oriented goals. Therefore micro-alloyed steels and high-strength aluminium materials are included in the multi-material mix of the car body. In this context self-pierce riveting has become established for joining in body-in-white production. For the dimensioning of the joint, numerical simulation is increasingly being used. In order to make reliable predictions about joint quality, knowledge of the friction in the joining process is necessary and needs to be identified experimentally. In previous investigations, the process parameters in the friction test were not comparable to the joining process. Therefore, a new friction test method is presented in this paper, where the process conditions are comparable between joining and friction testing especially regarding the interface pressure. The local joining process parameters between rivet and sheet are derived numerically. In the framework of the investigations, the influences of the local joining process parameters, like interface pressure, relative velocity and temperature, on the friction are investigated and mapped close to the joining process. Additionally a comparison of different rivet coatings is carried out. The rivet contact to the sheet metal HX340LAD as well with aluminium EN AW-5182 is taken into account.


Influence of heat treatment on the suitability for clinching of the aluminium casting alloy AlSi9

M. Neuser, M. Böhnke, O. Grydin, M. Bobbert, M. Schaper, G. Meschut, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications (2022), 146442072210758

<jats:p> In many manufacturing areas, multi-material designs are implemented in which individual components are joined together to form complex structures with numerous joints. For example, in the automotive sector, cast components are used at the junctions of the body and joined with different types of sheet metal and extruded profiles. To be able to join structures consisting of different materials, alternative joining technologies have emerged in recent years. This includes clinching, which allows assembling of two or more thin sheet metal and casting parts by solely cold forming the material. Clinching the brittle and usually less ductile cast aluminium alloys remains a challenge because the brittle character of the cast aluminium alloys can cause cracks during the forming of the clinched joint. In this study, the influence of the heat treatment time of an aluminium casting alloy AlSi9 on the joinability in the clinching process is investigated. Specific heat treatment of the naturally hard AlSi9 leads to a modification of the eutectic microstructure, which can increase ductility. Based on this, it will be examined if specific clinching die geometries can be used, which achieve an optimized geometrical formation of the clinched joint. The load-bearing capacities of the clinched joints are determined and compared by shear tensile and head tensile tests. Furthermore, the joints are examined microscopically to investigate the influence of the heat treatment on the failure behaviour during the load-bearing tests as well as crack initiation within the joining process. </jats:p>


Influence of cutting clearance and punch geometry on the stress state in small punch test

M. Otroshi, G. Meschut, Engineering Failure Analysis (2022), 136(c)

The presented paper aims to characterize the damage and fracture behavior of HX340LAD Micro-Alloyed steels using small punch test. Variations with respect to punch geometries and cutting clearance are made to describe the damage behavior of the material under different loading conditions. Experimental investigations are conducted to identify the crack initiation in the specimens. Furthermore, the numerical FEM simulations are performed to identify the stress state at crack initiation. It is shown that different stress states from shear to biaxial tension can be achieved by changing the geometries of punch and varying the cutting clearance. Moreover, it is presented how changing the configurations can influence the stress state variables: Triaxiality and lode angle parameter.


Systematisierung einer rechnergestützten Auswertemethode zur Versagensanalyse geklebter Verbindungen

N. Chudalla, D. Teutenberg, G. Meschut, M. Schneider, D. Smart, in: 22. Kolloquium: Gemeinsame Forschung in der Klebtechnik, 2022


Development of a rivet geometry for solid self-piercing riveting of thermally loaded CFRP-metal joints in automotive construction

J. Vorderbrüggen, D. Köhler, B. Grüber, J. Troschitz, M. Gude, G. Meschut, Composite Structures (2022), 291, 115583

DOI


Consideration of the manufacturing history of sheet metal components for the adaptation of a clinching process

P. Heyser, S. Wiesenmayer, P. Frey, T. Nehls, C. Scharr, W. Flügge, M. Merklein, G. Meschut, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications (2022), 146442072210775

The process chain for the manufacturing of sheet metal components in mass production includes various cutting and forming operations, which influence the resulting properties of the parts and therefore subsequent manufacturing steps, such as clamping and joining. It is shown that clamping of the components leads to superimposed residual stresses and geometry changes. Therefore, the part properties differ from the initial state of the semifinished products, which has to be considered in the design of clinched joints. This paper presents an approach for coupled determination of the properties of semifinished and finished parts during deep drawing and clamping as well as their effects on the joint quality during clinching. One method for the effective and efficient determination of the properties of semifinished products and components during production is using process data from the preceding manufacturing processes, which is concretely presented in this work. In addition to the interconnection of the entire production chain, it is necessary to define relevant process data for each individual manufacturing step and to correlate the data with the material properties reliably. Therefore, the cross-process interactions of different steps of the process chain for the manufacturing of sheet metal components and the effect of process variations on subsequent manufacturing steps are investigated. Consequently, the boundary conditions for a mechanical joining process based on data from preceding process steps can be predicted.


Investigation of the three-dimensional stress state during loading of self-piercing riveted joints

M. Otroshi, G. Meschut. Investigation of the three-dimensional stress state during loading of self-piercing riveted joints. 2022.


Provision of cross-domain knowledge in mechanical joining using ontologies

C. Zirngibl, P. Kügler, J. Popp, C.R. Bielak, M. Bobbert, D. Drummer, G. Meschut, S. Wartzack, B. Schleich, Production Engineering (2022)

Since the application of mechanical joining methods, such as clinching or riveting, offers a robust solution for the generation of advanced multi-material connections, the use in the field of lightweight designs (e.g. automotive industry) is steadily increasing. Therefore, not only the design of an individual joint is required but also the dimensioning of the entire joining connection is crucial. However, in comparison to thermal joining techniques, such as spot welding, the evaluation of the joints’ resistance against defined requirements (e.g. types of load, minimal amount of load cycles) mainly relies on the consideration of expert knowledge, a few design principles and a small amount of experimental data. Since this generally implies the involvement of several domains, such as the material characterization or the part design, a tremendous amount of data and knowledge is separately generated for a certain dimensioning process. Nevertheless, the lack of formalization and standardization in representing the gained knowledge leads to a difficult and inconsistent reuse, sharing or searching of already existing information. Thus, this contribution presents a specific ontology for the provision of cross-domain knowledge about mechanical joining processes and highlights two potential use cases of this ontology in the design of clinched and pin joints.</jats:p>


Numerical and experimental identification of fatigue crack initiation sites in clinched joints

L. Ewenz, C.R. Bielak, M. Otroshi, M. Bobbert, G. Meschut, M. Zimmermann, Production Engineering (2022), 16(2-3), pp. 305-313

<jats:title>Abstract</jats:title><jats:p>In this paper, a study based on experimental and numerical simulations is performed to analyze fatigue cracks in clinched joints. An experimental investigation is conducted to determine the failure modes of clinched joints under cyclic loading at different load amplitudes with single-lap shear tests. In addition, numerical FEM simulations of clinching process and subsequent shear loading are performed to support the experimental investigations by analyzing the state of stresses at the location of failure. An attempt is made to explain the location of crack initiation in the experiments using evaluation variables such as contact shear stress and maximum principal stress.</jats:p>


Bauteilschonendes Entfügen struktureller Klebverbindungen durch Kälte

N. Chudalla, G. Meschut, A. Bartley, T.M. Wibbeke, adhäsion KLEBEN &amp; DICHTEN (2022), 66(4), pp. 34-37

DOI


Influence of curing-induced pre-deformations on the mechanical properties of adhesively bonded joints in steel-intensive mixed-material structures

F. Beule, D. Teutenberg, G. Meschut, T. Aubel, A. Matzenmiller. Influence of curing-induced pre-deformations on the mechanical properties of adhesively bonded joints in steel-intensive mixed-material structures. 2022.


Investigation of leak tightness for bonded steel joints induced by mechanical and corrosive load for use in battery housings

T. Schmolke, G. Meschut. Investigation of leak tightness for bonded steel joints induced by mechanical and corrosive load for use in battery housings. 2022.


Untersuchung von Klebverbindungen für Batteriegehäuse

T. Schmolke, G. Meschut, F. Rieker, D. Meinderink, G. Grundmeier, adhäsion KLEBEN & DICHTEN (2022), 66, pp. 40-43

DOI


Disjoining and repair strategies of structural joints in automotive lightweight structures

N. Chudalla, A. Bartley, J. Ditter, G. Meschut, T.M. Wibbeke, 2022



Global energy release rate of small penny-shaped cracks in hyperelastic materials under general stress conditions

T. Duffe, G. Kullmer, K. Tews, T. Aubel, G. Meschut, Theoretical and Applied Fracture Mechanics (2022)

DOI


Numerical investigation of the clinched joint loadings considering the initial pre-strain in the joining area

S. Martin, C.R. Bielak, M. Bobbert, T. Tröster, G. Meschut, Production Engineering (2022)

<jats:title>Abstract</jats:title><jats:p>The components of a body in white consist of many individual thin-walled sheet metal parts, which usually are manufactured in deep-drawing processes. In general, the conditions in a deep-drawing process change due to changing tribology conditions, varying degrees of spring back, or scattering material properties in the sheet blanks, which affects the resulting pre-strain. Mechanical joining processes, especially clinching, are influenced by these process-related pre-strains. The final geometric shape of a clinched joint is affected to a significant level by the prior material deformation when joining with constant process parameters. That leads to a change in the stiffness and force transmission in the clinched joint due to the different geometric dimensions, such as interlock, neck thickness and bottom thickness, which directly affect the load bearing capacity. Here, the influence of the pre-straining in the deep drawing process on the force distribution in clinch points in an automotive assembly is investigated by finite-element models numerically. In further studies, the results are implemented in an optimization tool for designing clinched components. The methodology starts with a pre-straining of metal sheets. This step is followed by 2D rotationally symmetric forming simulations of the joining process. The resulting mesh of each forming simulation is rotated and 3D models are obtained. The clinched joint solid model with pre-strains is used further to determine the joint stiffnesses. With the simulation of the same test set-up with an equivalent point-connector model, the equivalent stiffness for each pre-strain combination is determined. Simulations are performed on a clinched component to assess the influence of pre-strain and sheet thinning on the clinched joint loadings by using the equivalent stiffnesses. The investigations clearly show that for the selected component, the loadings at the clinch points are dependent on the sheet thinning and the stiffnesses due to pre-strain. The magnitude of the influence varies depending on the quantity considered. For example, the shear force is more sensitive to the joint stiffness than to the sheet thinning.</jats:p>


Functionality Study of an Optical Measurement Concept for Local Force Signal Determination in High Strain Rate Tensile Tests

M. Böhnke, E. Unruh, S. Sell, M. Bobbert, D. Hein, G. Meschut, Key Engineering Materials (2022), 926, pp. 1564-1572

<jats:p>Many mechanical material properties show a dependence on the strain rate, e.g. yield stress or elongation at fracture. The quantitative description of the material behavior under dynamic loading is of major importance for the evaluation of crash safety. This is carried out using numerical methods and requires characteristic values for the materials used. For the standardized determination of dynamic characteristic values in sheet metal materials, tensile tests performed according to the guideline from [1]. A particular challenge in dynamic tensile tests is the force measurement during the test. For this purpose, strain gauges are attached on each specimen, wired to the measuring equipment and calibrated. This is a common way to determine a force signal that is as low in vibration and as free of bending moments as possible. The preparation effort for the used strain gauges are enormous. For these reasons, an optical method to determine the force by strain measurement using DIC is presented. The experiments are carried out on a high speed tensile testing system. In combioantion with a 3D DIC high speed system for optical strain measurement. The elastic deformation of the specimen in the dynamometric section is measured using strain gauges and the optical method. The measured signals are then compared to validate the presented method. The investigations are conducted using the dual phase steel material HCT590X and the aluminum material EN AW-6014 T4. Strain rates of up to 240 s-1 are investigated.</jats:p>


Numerical investigation of a friction test to determine the friction coefficients for the clinching process

C.R. Bielak, M. Böhnke, M. Bobbert, G. Meschut, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications (2022), 146442072210934

<jats:p> Clinching as a mechanical joining process has become established in many areas of car body. In order to predict relevant properties of clinched joints and to ensure the reliability of the process, it is numerically simulated during the product development process. The prediction accuracy of the simulated process depends on the implemented friction model. Therefore, a new method for determining friction coefficients in sheet metal materials was developed and tested. The aim of this study is the numerical investigation of this experimental method by means of FE simulation. The experimental setup is modelled in a 3D numerical simulation taking into account the process parameters varying in the experiment, such as geometric properties, contact pressure and contact velocity. Furthermore, the contact description of the model is calibrated via the experimentally determined friction coefficients according to clinch-relevant parameter space. It is shown that the assumptions made in the determination of the experimental data in preliminary work are valid. In addition, it is investigated to what extent the standard Coulomb friction model in the FEM can reproduce the results of the experimental method. </jats:p>


Experimental and Numerical Investigation on Manufacturing-Induced Pre-Strain on the Load-Bearing Capacity of Clinched Joints

C.R. Bielak, M. Böhnke, M. Bobbert, G. Meschut, Key Engineering Materials (2022), 926, pp. 1516-1526

<jats:p>Background. Clinching is a conventional cold forming process in which two or more sheets can be joined without auxiliary parts. A pre-forming of the parts to be joined, which is introduced by previous manufacturing steps, has an influence on the joining result. When considering the suitability for joining with regard to the formability of the materials, the influence of the preforming steps must be taken into account. The influences of strain hardening and sheet thickness on the joining properties must be investigated. In this context, a Finite Element Method (FEM) based metamodel analysis of the clinching process was carried out in [1] to investigate the robustness of the clinching process with respect to the different material pre-strains. In [2], the method was extended to the load bearing simulation.Procedure. The metamodel from preliminary work based on various FE models, which predicts the load-bearing capacity of a clinched joint influenced by pre-straining, is compared here with experimental data and the accuracy of the metamodel prediction is discussed. For this purpose an experimental procedure was further develop which allows the preforming of metal sheets from which joining specimens can be separated with a certain degree of unidirectional deformation. In the study, the procedure for preparing the joint specimens and the results of the loading tests are presented. Different possible relevant pre-strain combinations are investigated and compared with the simulation results, to validate the FE models and choose suitable metamodel.</jats:p>


Development of a Modified Punch Test for Investigating the Failure Behavior in Sheet Metal Materials

M. Böhnke, C.R. Bielak, M. Bobbert, G. Meschut, in: The Minerals, Metals &amp; Materials Series, Springer International Publishing, 2022

DOI


2021

Dämpfungseigenschaften geklebter Verbindungen - Potenzialanalyse und Klebstoffcharakterisierung

J. Göddecke, G. Meschut, J. Damm, M. Albiez, T. Ummenhofer, adhäsion KLEBEN & DICHTEN (2021), pp. 14-23

DOI



Fiber response to pin penetration in dry woven fabric using numerical analysis

M. Droß, P. Heyser, G. Meschut, A. Hürkamp, K. Dröder, Journal of Advanced Joining Processes (2021), 100083


Mechanisches Fügen von FKV-FKV-Verbindungen

D. Han, G. Meschut, 2021

Within the scope of the research project, four new mechanical joining processes for the singlestage, pre-hole-free joining of FRP-FRP joints were further developed. For this purpose, the joining processes under consideration were first implemented on existing equipment at the research institute. Based on the successful adaptation of the joining processes, characteristics of the joints were documented by means of micrographs and observation of external characteristics, on the basis of which measures for process modification were derived. The process modifications were carried out on a process-specific basis for a selected GFRPGFRP joint. The aim was to improve the joint quality, in particular with regard to the reduction of laminate damage, by means of targeted element and tool development in addition to the increase in process stability. Based on these results, a realistic suitability evaluation of the joining methods was carried out with regard to process and manufacturing flexibility. As a result, two self-piercing riveting processes, which showed the greatest suitability potential, were examined in more detail to analyse the application limits. In the process, the joints were sampled on further material combinations with varied fibre and matrix systems. In addition, joints with adhesive were investigated, in which the influence of the adhesive viscosity on the joint properties was analysed. The joint properties of the new joining method were then comprehensively determined by tensile tests under quasi-static, cyclic loads. Finally, the behaviour of the optimised joints under corrosive load was characterised in the salt spray test. Through the targeted process modifications in this project, the FRP-FRP joints can be joined with less damage, enabling improved joint quality in the FRP-based components.


Effect of low-profile additives on the durability of adhesively bonded Sheet Moulding Compound (SMC)

V. Aßmuth, G. Meschut, International Journal of Adhesion and Adhesives (2021), 112, 103036

DOI


Konzeptentwicklung für ein Stahlbatteriegehäuse

T. Schmolke, G. Meschut, stahl. (2021), 3-4 / 2021, pp. 37-39


Modeling of adhesives in crash simulation under consideration of manufacturing processes

M. Helbig, A. Haufe, F. Beule, T. Aubel, G. Meschut, S. Jamei, F. Fürle, S. Lossau, A. Droste, H. Gleich, K. Kose, D. Sommer, S. Facciotto. Modeling of adhesives in crash simulation under consideration of manufacturing processes. 2021.


DigiBody - Optimizing of Joining Technology

M. Helbig, A. Haufe, F. Beule, T. Aubel, G. Meschut, S. Jamei, F. Fürle, S. Lossau, A. Droste, H. Gleich, K. Kose, D. Sommer, S. Facciotto. DigiBody - Optimizing of Joining Technology. 2021.



Analyse des Versagensverhaltens geklebter Stahl Verbindungen beim werkstoffschonenden Entfügen in der Karosserieinstandsetzung

N. Chudalla, G. Meschut, A. Bartley, T.M. Wibbeke. Analyse des Versagensverhaltens geklebter Stahl Verbindungen beim werkstoffschonenden Entfügen in der Karosserieinstandsetzung. 2021.


Joining of ultra-high-strength steels using resistance element welding on conventional resistance spot welding guns

H. Günter, G. Meschut, Welding in the World (2021)

DOI


Joining of press-hardened profiles for the mixed-intensive lightweight structural design in electric vehicles

H. Günter, G. Meschut, D. Fuss, K. Werner, M. Bangel, D. Rotzsche, M. Uffelmann, N. Oleff, in: Joining in Car Body Engineering 2021, 2021


Robotergestütztes manuelles mechanisches Fügen – RoboterFügen

S. Neumann, G. Meschut, F. Schmatz, W. Flügge, 2021


Analyse rezepturabhängiger und alterungsbedingter Enthaftungserscheinungen geklebter SMC-Bauteile

V. Aßmuth, D. Teutenberg, G. Meschut, in: 10. Doktorandenseminar Klebtechnik, DVS Media GmbH, 2021


Development of an adaptive, sensor-based FDS-robot-system

M. Ivanjko, R. Beck, G. Meschut, J. Zweck, T. Richter, 2021



Influence of the Rivet Coating on the Friction during Self-Piercing Riveting

B. Uhe, C. Kuball, M. Merklein, G. Meschut, Key Engineering Materials (2021), 883, pp. 11-18

The number of multi-material joints is increasing as a result of lightweight design. Self-piercing riveting (SPR) is an important mechanical joining technique for multi-material structures. Rivets for SPR are coated to prevent corrosion, but this coating also influences the friction that prevails during the joining process. The aim of the present investigation is to evaluate this influence. The investigation focuses on the common rivet coatings Almac® and zinc-nickel with topcoat as well as on uncoated rivet surfaces. First of all, the coating thickness and the uniformity of the coating distribution are analysed. Friction tests facilitate the classification of the surface properties. The influence of the friction on the characteristic joint parameters and the force-stroke curves is analysed by means of experimental joining tests. More in-depth knowledge of the effects that occur is achieved through the use of numerical simulation. Overall, it is shown that the surface condition of the rivet has an impact on the friction during the joining process and on the resulting joint. However, the detected deviations between different surface conditions do not restrict the operational capability of SPR and the properties of uncoated rivet surfaces, in particular, are similar to those of Almac®-coated rivets. It can thus be assumed that SPR with respect to the joining process is also possible without rivet coating in principle.


Strength of self-piercing riveted Joints with conventional Rivets and Rivets made of High Nitrogen Steel

B. Uhe, C. Kuball, M. Merklein, G. Meschut, 2021

The use of high-strength steel and aluminium is rising due to the intensified efforts being made in lightweight design, and self-piercing riveting is becoming increasingly important. Conventional rivets for self-piercing riveting differ in their geometry, the material used, the condition of the material and the coating. To shorten the manufacturing process, the use of stainless steel with high strain hardening as the rivet material represents a promising approach. This allows the coating of the rivets to be omitted due to the corrosion resistance of the material and, since the strength of the stainless steel is achieved by cold forming, heat treatment is no longer required. In addition, it is possible to adjust the local strength within the rivet. Because of that, the authors have elaborated a concept for using high nitrogen steel 1.3815 as the rivet material. The present investigation focusses on the joint strength in order to evaluate the capability of rivets in high nitrogen steel by comparison to conventional rivets made of treatable steel. Due to certain challenges in the forming process of the high nitrogen steel rivets, deviations result from the targeted rivet geometry. Mainly these deviations cause a lower joint strength with these rivets, which is, however, adequate. All in all, the capability of the new rivet is proven by the results of this investigation.


Reduzierung der Flanschbreiten beim Widerstandspunktschweißen durch Einsatz exzentrischer Elektrodenkappengeometrien

C. Böhne, G. Tümkaya, G. Meschut. Reduzierung der Flanschbreiten beim Widerstandspunktschweißen durch Einsatz exzentrischer Elektrodenkappengeometrien. 2021.




Joining of press-hardened profiles for the mixed-intensive lightweight structural design in electric vehicles

D. Rotzsche, G. Meschut, D. Fuss, M. Bangel, M. Uffelmann, K. Werner, N. Oleff, H. Günter, in: Joining in Car Body Engineering 2021, 2021


Entwicklung einer gewichtsoptimierten Batteriegehäusestruktur für Volumenfahrzeuge

T. Schmolke, C. Krüger, D. Merdivan, S. Spohr, G. Meschut, Forschungsvereinigung Automobiltechnik (FAT) , 2021


Self-Piercing Riveting Using Rivets Made of Stainless Steel with High Strain Hardening

B. Uhe, C. Kuball, M. Merklein, G. Meschut, in: Forming the Future - Proceedings of the 13th International Conference on the Technology of Plasticity. The Minerals, Metals & Materials Series., Springer, 2021, pp. 1495-1506

Self-piercing riveting is an established technique for joining multi-material structures in car body manufacturing. Rivets for self-piercing riveting differ in their geometry, the material used, the condition of the material and their surface condition. To shorten the manufacturing process by omitting the heat treatment and the coating process, the authors have elaborated a concept for the use of stainless steel with high strain hardening as a rivet material. The focus of the present investigation is on the evaluation of the influences of the rivet’s geometry and material on its deformation behaviour. Conventional rivets of types P and HD2, a rivet with an improved geometry made of treatable steel 38B2, and rivets made of the stainless steels 1.3815 and 1.4541 are examined. The analysis is conducted by means of multi-step joining tests for two material combinations comprising high-strength steel HCT70X and aluminium EN AW-5083. The joints are cut to provide a cross-section and the deformation behaviour of the different rivets is analysed on the basis of the measured changes in geometry and hardness. In parallel, an examination of the force-stroke curves provides further insights. It can be demonstrated that, besides the geometry, the material strength, in particular, has a significant influence on the deformation behaviour of the rivet. The strength of steel 1.4541 is seen to be too low for the joining task, while the strength of steel 1.3815 is sufficient, and hence the investigation confirms the capability of rivets made of 1.3815 for joining even challenging material combinations.


A method for three-dimensional modelling of the shear-clinching process

D. Han, C. Yang, G. Meschut, ESAFORM 2021 (2021)

<jats:p>Three-dimensional modelling enables to determine the in-plane material flow in asymmetrical situation. Thus, the distortion of the sheets to be joined can be characterized more exactly. This study shows a method for building up a three-dimensional shear-clinching framework without damage criteria. In fact, the die-sided sheet in shear-clinching was designed as a pre-punched sheet and slugs. The material separation in the die-sided joining partner, which in two-dimensional simulation is often described by macro- and micromechanical fracture criteria, was realised in this study based on a defined contact condition. By means of a shear-cutting simulation, a correlation between the break angle and the separation stress was determined, which was used as a separation criterion in the shear-clinching simulation. The separation line was confirmed using post-particles. To validate this model, the results of the simulation using a quadratic single-point specimen were compared to the experiments with respect to the distortion of the joining partner. In general, the built three-dimensional framework provides for further tool developments with regard to the reduction of distortion in shear-clinching.</jats:p>





Intrinsische Hybridverbunde für Leichtbautragstrukturen

S. Sander, M. Bobbert, G. Meschut, Springer Vieweg, 2021, pp. 332


Mechanical joining of glass fibre reinforced polymer (GFRP) through an innovative solid self-piercing rivet

D. Han, K. Yang, G. Meschut, Journal of Materials Processing Technology (2021), 117182

DOI


Methodenentwicklung zur Langzeitprognose von Klebverbindungen bei kombinierter Temperatur- und Medieneinwirkung

S. Sander, D. Teutenberg, G. Meschut, A. Matzenmiller, in: 21. Kolloquium Gemeinsame Forschung in der Klebtechnik, 2021


Development of a Method for the Identification of Friction Coefficients in Sheet Metal Materials for the Numerical Simulation of Clinching Processes

M.S. Rossel, M. Böhnke, C.R. Bielak, M. Bobbert, G. Meschut, in: Sheet Metal 2021, Trans Tech Publications Ltd, 2021, pp. 81-88

In order to reduce the fuel consumption and consequently the greenhouse emissions, the automotive industry is implementing lightweight constructions in the body in white production. As a result, the use of aluminum alloys is continuously increasing. Due to poor weldability of aluminum in combination with other materials, mechanical joining technologies like clinching are increasingly used. In order to predict relevant characteristics of clinched joints and to ensure the reliability of the process, it is simulated numerically during product development processes. In this regard the predictive accuracy of the simulated process highly depends on the implemented friction model. In particular, the frictional behavior between the sheet metals affects the geometrical formation of the clinched joint significantly. This paper presents a testing method, which enables to determine the frictional coefficients between sheet metal materials for the simulation of clinching processes. For this purpose, the correlation of interface pressure and the relative velocity between aluminum sheets in clinching processes is investigated using numerical simulation. Furthermore, the developed testing method focuses on the specimen geometry as well as the reproduction of the occurring friction conditions between two sheet metal materials in clinching processes. Based on a methodical approach the test setup is explained and the functionality of the method is proven by experimental tests using sheet metal material EN AW6014.


Einfluss fertigungsbedingter Toleranzen auf das Versagens- und Verformungsverhalten mechanisch gefügter Verbindungen unter Crashbelastung

V. Olfert, G. Meschut, D. Hein, P. Rochel, S. Sommer. Einfluss fertigungsbedingter Toleranzen auf das Versagens- und Verformungsverhalten mechanisch gefügter Verbindungen unter Crashbelastung. 2021.


Methodenentwicklung zur Versagensanalyse aufgrund der Aushärtung vorgeschädigter Klebverbindungen in stahlintensiven Mischbaustrukturen

F. Beule, D. Teutenberg, G. Meschut, T. Aubel, A. Matzenmiller. Methodenentwicklung zur Versagensanalyse aufgrund der Aushärtung vorgeschädigter Klebverbindungen in stahlintensiven Mischbaustrukturen. 2021.


Methodenentwicklung zur numerischen Lebensdauerprognose von hyperelastischen Klebverbindungen infolge zyklischer Beanspruchung mittels bruchmechanischer Ansätze

K. Tews, T.. Aubel, D. Teutenberg, G. Meschut, T. Duffe, G. Kullmer, in: DECHEMA, Gesellschaft für Chemische Technik und Biotechnologie e.V. (Ed.), 21. Kolloquium: Gemeinsame Forschung in der Klebtechnik, 2021


Bruchmechanische Lebensdauervorhersage für hyperelastische Klebverbindungen

T. Duffe, G. Kullmer, K. Tews, T. Aubel, G. Meschut, in: 51. DVM-Tagung, Arbeitskreis Bruchmechanik und Bauteilsicherung, 2021


Concept development of a method for identifying friction coefficients for the numerical simulation of clinching processes

M. Böhnke, M.S. Rossel, C.R. Bielak, M. Bobbert, G. Meschut, The International Journal of Advanced Manufacturing Technology (2021)

<jats:title>Abstract</jats:title><jats:p>In order to reduce fuel consumption and thus pollutant emissions, the automotive industry is increasingly developing lightweight construction concepts that are accompanied by an increasing usage of aluminum materials. Due to poor weldability of aluminum in combination with other materials, mechanical joining methods such as clinching were developed and established in series production. In order to predict the relevant characteristics of clinched joints and to ensure the reliability of the process, it is simulated numerically during product development processes. In this regard, the predictive accuracy of the simulated process highly depends on the implemented friction model. In particular, the frictional behavior between the sheet metals as well as between the sheet metal and clinching tools has a significant impact on the geometrical formation of the clinched joint. No testing methods exist that can sufficiently investigate the frictional behavior in sheet materials, especially under high interface pressures, different relative velocities, and long friction paths, while allowing a decoupled consideration of the test parameters. This paper describes the development of further testing concepts based on a proven tribo-torsion test method for determining friction coefficients between sheet metal materials for the simulation of clinching processes. For this purpose, the correlation of interface pressure and the relative velocity between aluminum and steel sheet material in clinching processes is investigated using numerical simulation. Based on these findings, the developed concepts focus on determining friction coefficients at interface pressures of the above materials, yield stress, as well as the reproduction of the occurring friction conditions between sheet metal materials and tool surfaces in clinching processes using tool substitutes. Furthermore, wear investigations between sheet metal material and tool surface were carried out in the friction tests with subsequent EDX analyses of the frictioned tool surfaces. The developed method also allows an optical deformation measurement of the sheet metal material specimen by means of digital image correlation (DIC). Based on a methodological approach, the test setups and the test systems used are explained, and the functionality of the concepts is proven by experimental tests using different sheet metal materials.</jats:p>


Influence of various procedures for the determination of flow curves on the predictive accuracy of numerical simulations for mechanical joining processes

M. Böhnke, F. Kappe, M. Bobbert, G. Meschut, Materials Testing (2021), 63(6), pp. 493-500

The predictive quality of numerical simulations for mechanical joining processes depends on the implemented material model, especially regarding the plasticity of the joining parts. Therefore, experimental material characterization processes are conducted to determine the material properties of sheet metal and generate flow curves. In this regard, there are a number of procedures which are accompanied by varying experimental efforts. This paper presents various methods of determining flow curves for HCT590X as well as EN AW-6014, including varying specimen geometries and diverse hardening laws for extrapolation procedures. The flow curves thus generated are compared considering the variety of plastic strains occurring in mechanical joining processes. The material data generated are implemented in simulation models for the joining technologies, clinching and self-piercing riveting. The influence of the varied methods on the predictive accuracy of the simulation model is analysed. The evaluation of the differing flow curves is achieved by comparing the geometric formation of the joints and the required joining forces of the processes with experimentally investigated joints.





Selective application of different forming temperatures for individual process stages in a rivet manufacturing process with high nitrogen steel

C. Kuball, B. Uhe, G. Meschut, M. Merklein. Selective application of different forming temperatures for individual process stages in a rivet manufacturing process with high nitrogen steel. 2021.


Joining suitability of cast aluminium for self-piercing riveting

M. Neuser, F. Kappe, M. Busch, O. Grydin, M. Bobbert, M. Schaper, G. Meschut, T. Hausotte, IOP Conference Series: Materials Science and Engineering (2021), 012005

DOI


The influence of manufacturing processes and optical measurement methods on the damage behavior of HX340LAD micro-alloyed steels

M. Otroshi, G. Meschut, A. Nesakumar, Journal of Manufacturing Engineering (2021), 16(3), pp. 70-76

This study deals with the damage behavior of metallic materials by the application of different manufacturing processes and using different optical measurement methods to identify the crack initiation in the damage specimen. The study is intended to highlight the importance of considering manufacturing processes and optical measurement methods in a numerical simulation when analyzing the damage behavior of metallic materials. To describe the damage behavior of the material in the process chain simulations, it is important to calibrate the parameters of damage model more accurately. These parameters are determined using experimental investigation of desired damage specimens. In this regard, a selected damage specimen manufactured by different cutting processes is first experimentally and then numerically investigated. It is shown that the manufacturing process and the optical measurement methods influence the stress state analyzed in the numerical simulation.


Modeling of Stiffness Anisotropy in Simulation of Self-Piercing Riveted Components

M. Otroshi, G. Meschut, C.R. Bielak, L. Masendorf, A. Esderts, Key Engineering Materials (2021), 883, pp. 35-40

DOI


Service life estimation of self‐piercing riveted joints by linear damage accumulation

L. Masendorf, M. Wächter, A. Esderts, M. Otroshi, G. Meschut, Fatigue & Fracture of Engineering Materials & Structures (2021), pp. 15

DOI


Fügen und Trennen von Kfz-Karosseriestrukturen in Leichtbauweise

T.M. Wibbeke, A. Bartley, N. Chudalla, G. Meschut, in: Fahrzeug + Karosserie und kfz-betrieb (Hrsg,); Tagungsband zu den Würzburger Karosserie- und Schadenstagen 22./23. Oktober 2021, 2021


Clinching of Thermoplastic Composites and Metals—A Comparison of Three Novel Joining Technologies

B. Gröger, J. Troschitz, J. Vorderbrüggen, C. Vogel, R. Kupfer, G. Meschut, M. Gude, Materials (2021)

DOI


Computed tomography investigation of the material structure in clinch joints in aluminium fibre-reinforced thermoplastic sheets

B. Gröger, D. Köhler, J. Vorderbrüggen, J. Troschitz, R. Kupfer, G. Meschut, M. Gude, Production Engineering (2021)

<jats:title>Abstract</jats:title><jats:p>Recent developments in automotive and aircraft industry towards a multi-material design pose challenges for modern joining technologies due to different mechanical properties and material compositions of various materials such as composites and metals. Therefore, mechanical joining technologies like clinching are in the focus of current research activities. For multi-material joints of metals and thermoplastic composites thermally assisted clinching processes with advanced tool concepts are well developed. The material-specific properties of fibre-reinforced thermoplastics have a significant influence on the joining process and the resulting material structure in the joining zone. For this reason, it is important to investigate these influences in detail and to understand the phenomena occurring during the joining process. Additionally, this provides the basis for a validation of a numerical simulation of such joining processes. In this paper, the material structure in a joint resulting from a thermally assisted clinching process is investigated. The joining partners are an aluminium sheet and a thermoplastic composite (organo sheet). Using computed tomography enables a three-dimensional investigation that allows a detailed analysis of the phenomena in different joining stages and in the material structure of the finished joint. Consequently, this study provides a more detailed understanding of the material behavior of thermoplastic composites during thermally assisted clinching.</jats:p>


Experimentelle Untersuchung der Dämpfungseigenschaften geklebter Strukturen unter dynamischer Beanspruchung

J. Göddecke, G. Meschut, in: 11. Doktorandenseminar Klebtechnik, DVS Media GmbH, 2021


Hybridprofile für Trag- und Crashstrukturen

W. Drossel, M. Bobbert, M. Böhme, C. Dammann, A. Dittes, M. Gießmann, C. Hühne, J. Ihlemann, R. Kießling, T. Lampke, P. Lenz, R. Mahnken, G. Meschut, R. Müller, M. Nier, R. Prussak, M. Riemer, S. Sander, M. Schaper, I. Scharf, M. Scholze, S. Schwöbel, S. Sharafiev, M. Sinapius, D. Stefaniak, T. Tröster, M.F.-. Wagner, Z. Wang, C. Zinn, in: Intrinsische Hybridverbunde für Leichtbautragstrukturen, 2021

DOI


Experimental failure analysis of adhesively bonded steel/CFRP joints under quasi-static and cyclic tensile-shear and peel loading

J. Kowatz, D. Teutenberg, G. Meschut, International Journal of Adhesion and Adhesives (2021), 107, 102851

DOI


2020

Simple Determination of Fast Curing Parameters for Bonded Structures

J. Ditter, T. Aubel, G. Meschut, adhesion ADHESIVES + SEALANTS (2020)(1)


Improvement of a rivet geometry for the self-piercing riveting of high-strength steel and multi-material joints

B. Uhe, C. Kuball, M. Merklein, G. Meschut, Production Engineering (2020), 14, pp. 417-423

As a result of lightweight design, increased use is being made of high-strength steel and aluminium in car bodies. Self-piercing riveting is an established technique for joining these materials. The dissimilar properties of the two materials have led to a number of different rivet geometries in the past. Each rivet geometry fulfils the requirements of the materials within a limited range. In the present investigation, an improved rivet geometry is developed, which permits the reliable joining of two material combinations that could only be joined by two different rivet geometries up until now. Material combination 1 consists of high-strength steel on both sides, while material combination 2 comprises aluminium on the punch side and high-strength steel on the die side. The material flow and the stress and strain conditions prevailing during the joining process are analysed by means of numerical simulation. The rivet geometry is then improved step-by-step on the basis of this analysis. Finally, the improved rivet geometry is manufactured and the findings of the investigation are verified in experimental joining tests.



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