A Review on the Modeling of the Clinching Process Chain - Part I: Design Phase

Abstract

In many areas of product manufacturing, constructions are often mechanically joined of different materials to realize assemblies of various complexity with numerous point-shaped connections. Thereby, clinching is a frequently used joining technology. For the prognosis of the joinability and the life cycle of a connection, numerical modeling of the complete joining process chain is essential, considering (i) the design phase, (ii) the joining process itself, and (iii) the resulting properties of the connection in the operational phase. This holistic modeling approach enables the comprehension of the complex cause-and-effect relationships in mechanical joining of different materials (e.g. aluminum, steel and fiber-reinforced composites). Furthermore, the interactions between the production process and the subsequent operational loadings and environmental influences require a transferable design method for load-adapted, mechanically joined assemblies. This paper is the first part (part I) of a series of reviews summarizing the current state of research on modeling and simulation of clinching. In this context, the present paper deals with the joining process chain and its challenges as well as methods for the modeling and the optimization of clinch joints in the design phase. The simulation of the clinching process is subject of part II. The influences of the operational phase, e.g. corrosion phenomena and fatigue crack growth, are considered in part III of our review series.

Keywords

• Mechanical joining
• Clinching
• Multi-material design
• Joint topology optimization
• Load path analysis
• Finite elements