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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.

Tests under variable amplitude loading on self-piercing riveted components with semi-tubular rivets result in longer service lives than those calculated by linear damage accumulation. An overview of the literature shows that damage sums greater than one are found for other types of riveted joints either, while an explanation for this unusual behavior is still missing. Therefore, this behavior is examined in more detail. A correlation is shown between the damage sum and the hardness of the load spectrum. Considering this correlation, the accuracy of the service life estimation can be improved significantly.

The so-called substitute models based on shell elements can be used to design the self-piercing riveted components economically and with sufficient accuracy. In this study, the SPR3 (Self-Piercing Rivet) model with anisotropic stiffness parameters implemented in commercial simulation software LS-DYNA is used to describe the stiffness of self-piercing riveted joints subjected to different loading conditions. The model provides the basis for the subsequent fatigue life estimation of self-piercing riveted joints under cyclic loading. By accurate prediction of the stiffness of self-piercing riveted joints subjected to cyclic loading, the accuracy of the fatigue life estimation can be improved. To identify the stiffness parameters, the self-piercing riveted joints are subjected to loading conditions: axial tension, shear tension, and bending. To validate the model, the specimens are simulated under different loading conditions and the results are compared to the experiments. It is shown that the model with anisotropic stiffness parameters predicts the stiffness of specimens more accurately compared to the model with isotropic stiffness parameter.

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