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This article describes the joining of thin metal sheets by a single stroke clinching process. Elastic-plastic and rigid-plastic finite element analysis were applied by employing Coulomb friction and constant shear friction in order to investigate the behavior of the clinch joint formation process. Four process variables, such as die diameter, die depth, groove width, and groove corner radius were selected to investigate the parametric effect on the clinch joint. The strength of clinch joints were evaluated by examining the separation strengths, such as peel strength and tensile shear strength, respectively. A failure diagram was constructed that summarizes the analysis results. The simulation results showed that die diameter and depth were the most decisive parameters for controlling the quality of the clinch joint, while the bottom's thickness was the most important evaluation parameter to determine the separation strengths.

The accuracy of the short bearing approximation is analyzed in this discussion. The results apply to Newtonian lubricants, and they can also be extended to non-Newtonian power-law lubricants. Reynolds’ lubrication equation is first solved by applying a regular perturbation expansion in pressure to the π film journal bearing; after this, a matched asymptotic expansion is applied to linear slider bearings. Approximate solutions are then compared with numerical solutions, to estimate the accuracy of the short bearing approximation. Finally, the accuracy of fluid film pressures predicted via short bearing theory is shown to depend upon three factors: the bearing aspect ratio, eccentricity ratio, and the partial-arc extent. Ocvirk’s short bearing series approximation—for finite bearing aspect ratio—is shown to become singular in the limit as the eccentricity ratio approaches unity. The one term π film Ocvirk solution is shown to be a nonconservative approximation to the journal bearing load capacity. A method to extend the accuracy of the short bearing approximation for partial-arcs and slider bearings is then presented.

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