Rigid-plastic and elastic-plastic finite element analysis on the clinching joint process of thin metal sheets

Abstract

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.

Clinching process for joining dissimilar materials: state of the art

“…They found that the punch corners with groove depth and die shape are the influential geometric parameters that enhanced the interlock length of the clinched joint. Another [16] showed that the die diameter and depth were the main critical geometrical factors that influence the quality of the joints. Kim [17] conducted an experimental study to estimate the optimal punch force to obtain the highest clinched resistance value where a series of tensile tests were implemented on the sheet metal clinched joint assembled with different punch force.…”

“…Jayasekara et al [16] examined the separation strength with the configuration of peel and tensileshear tests of the clinched joint of aluminum alloy 5754. The quality of the joints was estimated by examining the thickness of the neck, measuring the mechanical interlock length of the joint, and estimating the bottom thickness of the clinched [30] connection.…”

Recent and future development of the application of finite element analysis in clinching process

“…Jayasekara et al [12] investigated the clinching of AA 5754 metal sheets using rigid-plastic and elasto-plastic models with Coulomb friction and a constant shear friction. The process simulation was carried out using an axisymmetric model in FE commercial software, DEFORM-2D.…”

The Experimental Analysis of Forming and Strength of Clinch Riveting Sheet Metal Joint Made of Different Materials

“…Smaller die and punch diameters are dedicated in CL process for thin sheet metals. They result in a better lock in the overpress (cap part of the joint which is formed by the punch pressing the joined materials into the die) [18]. Forming joints of sheet metal of different thickness are often accompanied by the material fracture.…”