Process Optimization and Experimental Study on Heat-assisted Clinching of AZ31B Magnesium Alloy and Carbon Steel Sheets with Different Strength Levels

DENG Boran; ZHAO Tengxiang; CHENG Lingchao; QIU Ping; XIAO Hong

doi:10.3969/j.issn.1674-6457.2026.10.017

PDF(14696 KB)

Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (10) : 166-176. DOI: 10.3969/j.issn.1674-6457.2026.10.017

Advanced Joining Technology

Process Optimization and Experimental Study on Heat-assisted Clinching of AZ31B Magnesium Alloy and Carbon Steel Sheets with Different Strength Levels

DENG Boran^a, ZHAO Tengxiang^b, CHENG Lingchao^a, QIU Ping^a,*, XIAO Hong^b

Author information +

History +

Abstract

The work aims to employ the finite element simulation and response surface methodology to investigate the forming mechanism, tool improvement, and process optimization of heat-assisted clinching for AZ31B/Q345 sheets, and conduct experiments to evaluate the feasibility of clinching AZ31B magnesium alloy with carbon steel sheets of different strength levels. Taking AZ31B/Q345 sheets as the research objects, a two-dimensional axisymmetric finite element model was established to compare and analyze the evolution of joint morphology during the clinching process before and after tool improvement. Neck thickness and interlock value were selected as evaluation indexes, and the punch radius, die depth, and die radius were taken as variables to optimize the improved tool by response surface methodology. In addition, heat-assisted clinching experiments were carried out on AZ31B/Q235, AZ31B/Q345, and AZ31B/Q460 sheets to analyze the influence of different steel sheets on joint quality. Under the conventional tool condition, the upper AZ31B sheet was prone to reverse flow and warping, making it difficult to form an effective interlock, whereas under the improved tool condition, an effective interlock could be achieved. The die radius was more sensitive to neck thickness, while the die depth was more sensitive to interlock value. After optimization, a punch radius of 2.8 mm, a die depth of 1.5 mm, and a die radius of 3.9 mm were found to be reasonable. The improved tool can achieve effective clinching of AZ31B/Q235 and AZ31B/Q345 sheets. Since the strength of the Q460 sheet is excessively high, a preforming clinching process is adopted in this study to obtain effective joints.

Key words

AZ31B magnesium alloy / carbon steel sheet / clinching / improved tool / response surface optimization / preforming clinching

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

DENG Boran, ZHAO Tengxiang, CHENG Lingchao, QIU Ping, XIAO Hong. Process Optimization and Experimental Study on Heat-assisted Clinching of AZ31B Magnesium Alloy and Carbon Steel Sheets with Different Strength Levels[J]. Journal of Netshape Forming Engineering. 2026, 18(10): 166-176 https://doi.org/10.3969/j.issn.1674-6457.2026.10.017

References

[1] 王渠东. 镁合金及其成形技术[M]. 北京: 机械工业出版社, 2017: 1-2.
WANG Q D.Magnesium Alloys and Their Forming Technologies[M]. Beijing: China Machine Press, 2017: 1-2.
[2] REN L M, ZHANG S H, PALUMBO G, et al.Warm Deep Drawing of Magnesium Alloy Sheets-Formability and Process Conditions[J]. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2008, 222(11): 1347-1354.
[3] EWENZ L, KUCZYK M, ZIMMERMANN M.Effect of the Tool Geometry on Microstructure and Geometrical Features of Clinched Aluminum[J]. Journal of Advanced Joining Processes, 2022, 5: 100091.
[4] NEUGEBAUER R, KRAUS C, DIETRICH S.Advances in Mechanical Joining of Magnesium[J]. CIRP Annals, 2008, 57(1): 283-286.
[5] WEN T, HUANG Q, LIU Q, et al.Joining Different Metallic Sheets without Protrusion by Flat Hole Clinching Process[J]. The International Journal of Advanced Manufacturing Technology, 2016, 85(1): 217-225.
[6] ABE Y, MORI K, KATO T.Joining of High Strength Steel and Aluminium Alloy Sheets by Mechanical Clinching with Dies for Control of Metal Flow[J]. Journal of Materials Processing Technology, 2012, 212(4): 884-889.
[7] ABE Y, KATO T, MORI K I, et al.Mechanical Clinching of Ultra-High Strength Steel Sheets and Strength of Joints[J]. Journal of Materials Processing Technology, 2014, 214(10): 2112-2118.
[8] ABE Y, ISHIHATA S, MAEDA T, et al.Mechanical Clinching Process Using Preforming of Lower Sheet for Improvement of Joinability[J]. Procedia Manufacturing, 2018, 15: 1360-1367.
[9] WIESENMAYER S, GRASER M, MERKLEIN M.Influence of the Properties of the Joining Partners on the Load-Bearing Capacity of Shear-Clinched Joints[J]. Journal of Materials Processing Technology, 2020, 283: 116696.
[10] HUANG Z Q, YANAGIMOTO J.Dissimilar Joining of Aluminum Alloy and Stainless Steel Thin Sheets by Thermally Assisted Plastic Deformation[J]. Journal of Materials Processing Technology, 2015, 225: 393-404.
[11] HAN S L, WANG Z Y, WANG Z P, et al.Heat-Assisted Hole-Clinching Process for Joining Magnesium Alloy and Ultra-High-Strength Steel[J]. The International Journal of Advanced Manufacturing Technology, 2021, 115(1): 551-561.
[12] BABALO V, FAZLI A, SOLTANPOUR M.Experimental Study of the Mechanical Performance of the New High-Speed Mechanical Clinching[J]. International Journal of Lightweight Materials and Manufacture, 2021, 4(2): 218-236.
[13] PEREIRA J A C, KASAEI M M, CARBAS R J C, et al. Joining Magnesium and Aluminum Alloy Sheets by a Novel Hole Hemming Process[J]. Thin-Walled Structures, 2023, 187: 110758.
[14] FU L, ZHANG S Y, QIU P, et al.Optimization of Clinching Joint Process with Preforming between Ultra-High-Strength Steel and Aluminum Alloy Sheets[J]. Metals, 2024, 14(7): 767.
[15] DUAN J R, CHEN C.Experimental Investigation of Stepped Clinching for High Strength Steel and Aluminium Alloy[J]. Materials Today Communications, 2024, 40: 109893.
[16] QIU P, LU X X, DAI X W, et al.Center-Punching Mechanical Clinching Process for Aluminum Alloy and Ultra-High-Strength Steel Sheets[J]. Metals, 2024, 14(10): 1190.
[17] 欧阳潇, 秦登林, 赵升吨, 等. 无模无铆连接接头的塑性变形行为及工艺参数研究[J]. 塑性工程学报, 2024, 31(1): 41-49.
OUYANG X, QIN D L, ZHAO S D, et al.Research on Plastic Deformation Behaviors and Process Parameters of Dieless Clinching Joints[J]. Journal of Plasticity Engineering, 2024, 31(1): 41-49.
[18] OUDJENE M, BEN-AYED L, DELAMÉZIÈRE A, et al. Shape Optimization of Clinching Tools Using the Response Surface Methodology with Moving Least-Square Approximation[J]. Journal of Materials Processing Technology, 2009, 209(1): 289-296.
[19] LAMBIASE F, DI ILIO A.Optimization of the Clinching Tools by Means of Integrated FE Modeling and Artificial Intelligence Techniques[J]. Procedia CIRP, 2013, 12: 163-168.
[20] ROUX E, BOUCHARD P O.Kriging Metamodel Global Optimization of Clinching Joining Processes Accounting for Ductile Damage[J]. Journal of Materials Processing Technology, 2013, 213(7): 1038-1047.
[21] CHEN C, ZHAO S D, HAN X L, et al.Optimization of a Reshaping Rivet to Reduce the Protrusion Height and Increase the Strength of Clinched Joints[J]. Journal of Materials Processing Technology, 2016, 234: 1-9.
[22] ESHTAYEH M, HRAIRI M.Multi Objective Optimization of Clinching Joints Quality Using Grey-Based Taguchi Method[J]. The International Journal of Advanced Manufacturing Technology, 2016, 87(1): 233-249.
[23] WANG M H, XIAO G Q, LI Z, et al.Shape Optimization Methodology of Clinching Tools Based on Bezier Curve[J]. The International Journal of Advanced Manufacturing Technology, 2018, 94(5): 2267-2280.
[24] 胡威, 薛松, 何其其, 等. 基于翻孔试验的AZ31B镁合金薄板温成形特点研究[J]. 塑性工程学报, 2024, 31(5): 37-47.
HU W, XUE S, HE Q Q, et al.Research on Warm Forming Characteristics of AZ31B Magnesium Alloy Sheet Based on Hole-Flanging Test[J]. Journal of Plasticity Engineering, 2024, 31(5): 37-47.
[25] QIU P, LU X X, DENG B R, et al.Optimization of a Center-Punching Mechanical Clinching Process for High- Strength Steel DP980 and Aluminum Alloy AL5052 Sheets[J]. Metals, 2025, 15(12): 1388.