Numerical and experimental investigation of flat-clinch joint strength

Abstract The striving for energy savings by lightweight construction requires the combination of different materials with advantageous properties. For joining sheet metal components, clinching offers a good alternative to thermal processes. In contrast processes, microstructure in zone remains largely unaffected. Conventional clinch joints, however, have protrusion on underside joint, which restricts their use functional and visible surfaces. Flat-clinching minimizes this disadvantage using flat anvil instead die. Due flatness underside, it can be used This paper deals increase joint strength an auxiliary element (AJE) second forming stage. To achieve optimum improvement aluminum Al99.5 H14 save costs, AJE was varied numerically terms volume, material basic shape. geometric parameters (e.g., interlocking f neck thickness t n ) do not allow direct derivation strength. reason, 2D model extended first time include 3D load models (cross tension, shear tension). validate numerical results, optimized flat-clinch joints associated tests were implemented experimentally. improve process development.