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

Publikation: Beitrag in FachzeitschriftForschungsartikelBeigetragenBegutachtung

Beitragende

Abstract

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.

Details

OriginalspracheEnglisch
Aufsatznummer100402
Seitenumfang16
FachzeitschriftJournal of Advanced Joining Processes
Jahrgang13
Frühes Online-Datum22 Apr. 2026
PublikationsstatusElektronische Veröffentlichung vor Drucklegung - 22 Apr. 2026
Peer-Review-StatusJa

Externe IDs

ORCID /0000-0003-1370-064X/work/213786497
ORCID /0009-0006-8400-6144/work/213787020
ORCID /0000-0002-0169-8602/work/213787357
WOS 001756867800001

Schlagworte

Schlagwörter

  • Clinching, Fatigue failure model, Modeling and simulation, Process chain, Process simulation, Surrogate model