Analytical estimation of maximum shear strength in clinched joint using mean flow stress

Accurate prediction of the shear strength of clinched joints is essential for ensuring joint reliability while minimizing experimental and numerical effort. This study proposes an analytical method to estimate the maximum shear load of clinched joints under tensile loading. Four work-hardening models were evaluated using experimentally identified material properties, with explicit consideration of material anisotropy. Analytical predictions were validated against experimental shear test results. The anisotropic formulation combined with the Swift hardening law showed the best agreement with experiments, predicting a maximum shear load of 2000 N with an error of −1.43%. While the Voce model provides improved predictions under isotropic assumptions due to its saturation-type hardening behavior, the Swift model more accurately captures directional strain hardening when anisotropy is included. The proposed approach demonstrates enhanced predictive capability relative to conventional analytical models and offers a practical tool for clinched joint design, including the optimization of neck thickness and undercut geometry.