Testing and modelling of flow-drill screw connections under quasi-static loadings Johan Kolstø Sønstabø a,b , David Morin a,b,* , Magnus Langseth a,b a Centre for Advanced Structural Analysis (CASA), Norwegian University of Science and Technology (NTNU), NO-7491 Trondheim, Norway b Structural Impact Laboratory (SIMLab), Department of Structural Engineering, NTNU, NO-7491 Trondheim, Norway Abstract The behaviour of a flow-drill screw connection under different quasi-static loadings was simulated using finite element models with detailed solid element meshes. The numerical models were developed with a rate- independent isotropic hypoelastic-plastic material model. A process-effect analysis was conducted, including investigation of the microstructure as well as hardness tests. Based on the investigation, the process effects were considered negligible. A simple approach for building up the geometry of the connection was presented. An experimental programme consisting of five different single-connector tests was carried out to characterise the connection, and was presented in detail. Each test was simulated, allowing for one-to-one comparisons between tests and simulations. Satisfactory results were achieved. Keywords: Flow-drill screw, Connection, Finite element, Experiments, Automotive 1. Introduction 1 Flow-drill screws (FDS) are commonly used to join parts of dissimilar materials in the load-bearing structure of 2 cars. Since connections play important roles for the crashworthiness of vehicles, knowledge about their physical 3 behaviour under impact loadings is important for design decisions. Necessary knowledge and physical insight is 4 usually gained through extensive experimental programmes, which typically involve loading specimens consisting 5 of two or more plates joined with one or more connectors until failure (Sønstabø et al., 2015). Various loadings 6 are achieved by changing the specimen design and loading directions. 7 A limited number of experimental studies on FDS connections can be found in the open literature. Szlosarek 8 et al. (2013) presented a novel testing and analysis method. It was demonstrated for an FDS connection between 9 plates of a carbon fibre reinforced polymer and aluminium. Skovron et al. (2014) studied the FDS process for 10 a connection between sheets of aluminium alloy AA 5052-O. They explored feasible design space regions to 11 determine how process parameters affect the geometry of the assembled connection. Mechanical tests were 12 * Corresponding author Email address: [email protected] (David Morin) 1
Testing and modelling of flow-drill screw connections under quasi-static loadings
May 19, 2023
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