A novel sensitivity analysis on friction spot joining process performed on aluminum\polycarbonate sheets by simulation
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IJMF 10TH ANNIVERSARY - ADVANCES IN MATERIAL FORMING
A novel sensitivity analysis on friction spot joining process performed on aluminum\polycarbonate sheets by simulation Giuseppe Serratore 1 & Francesco Gagliardi 1 & Clara Argerich Martín 2 & Ruben Ibanez Pinilo 2 & Elias Cueto 3 & Luigino Filice 1 & Francisco Chinesta 4 Received: 22 April 2020 / Accepted: 7 July 2020 # The Author(s) 2020
Abstract The manufacturing research has been focusing on the improvement of product performance and lightweight design. The synergic effects between material properties and manufacturing solutions have been considered, extensively. Specifically, joining techniques have been developing with the aim to propose new suitable solutions considering dissimilarities in the properties of the materials that have to be combined. Setting of new manufacturing routes is, therefore, a demanding task. In this direction, there are several methods available in the scientific literature that are focused on sensitivity analysis or optimization/minimization techniques to reduce the necessary attempts or to find a solution/correlation among big data. In this work, the goal of obtaining high joint efficiency between Aluminum and Polycarbonate sheets by the Friction Spot Joining process is considered as a case study. This process must face two main issues, i.e., the mechanical, physical and chemical compatibilities between the parts and the integrity protection of the polymeric sheet near the joining area. The process parameters influences were analysed using numerical simulations performed by a commercial FE code. The number of executed analyses was reduced with a planned DoE. From these results, the Code2Vect algorithm was employed with the aim to visualize, efficiently, high-dimensional data and to evaluate the influences of some identified parameters on the process answer. Finally, a transfer function involving the input and output quantities of interest was derived in a compact representation by a Newton Raphson minimization technique. Keywords Mechanical fastening . Dissimilar materials . Friction spot joining . Machine learning . Code2Vect . Newton-Raphson
Introduction As continuously demanded by aerospace and automotive industries, academic and industrial research have been focusing on the development of lightweight components for pursuing both CO 2 reduction and performant
solutions through the combination of different lightweight materials such as Aluminum, Magnesium alloys and thermoplastic materials. In this context, the main goal is the development of peculiar techniques suitable to joint these materials through the optimization of advanced and sustainable connections.
* Giuseppe Serratore [email protected]
Francisco Chinesta [email protected]
Francesco Gagliardi [email protected]
1
DIMEG, University of Calabria, P. Bucci 45/C, 87036 Rende, Cs, Italy
Clara Argerich Martín [email protected]
2
PIMM, Arts et Métiers Institute of Technology, CNRS, CNAM, HESAM University, 151, boule-vard
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