Simulation-based process chain for aluminum clinched joints: Predicting geometry, strength, and failure behavior

Clinching is a mechanical joining process that can join different material and geometry combinations and does not require auxiliary joining parts. In order to exploit the full potential of the clinching process, a high level of process understanding is required. Physical modeling and numerical simulations are useful to deepen the process understanding and to analyze reciprocal influences within the entire process chain. By means of an exemplary clinched joint, we present different modeling approaches and simulation methods to analyze the clinching process itself, the load-bearing capacity behavior and the fatigue and failure behavior of the clinched joint. These simulation methods cover the entire process chain, enabling analysis of how different variables influence the behavior of the clinched joint. For instance, the impact of process-induced damage or residual stresses on static or cyclic failure of the joint is analyzed. Furthermore, simulation approaches with different levels of detail are considered, e.g. finely resolved finite element simulations of a clinched joint are compared to simplified connection elements, as used in large-scale component simulations. We provide recommendations on which variables have a significant impact on the process chain and which simulation methods are appropriate for specific numerical analyses.