Development of a numerical method for analyzing the robustness of clinching in versatile process chains

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Development of a numerical method for analyzing the robustness of clinching in versatile process chains

In many areas of product manufacturing individual components are usually joined together to form complex structures with numerous joints. Using mechanical joining technologies offers the possibility of joining structures with a wide range of material-geometry combinations. In order to realize the increasing number of varying products using different materials and designs within a process chain, they need to be versatile.

Open Access

2022-11-29T13:23:05Z

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https://www.mse-congress.de/program/scientific-program/?tx_dgmprogram_fullprogram%5Bsession%5D=9629&tx_dgmprogram_fullprogram%5Baction%5D=show&tx_dgmprogram_fullprogram%5Bcontroller%5D=Session&cHash=84006c1cdd38f631b19682a33e47111e

In many areas of product manufacturing individual components are usually joined together to form complex structures with numerous joints. Mechanical joining technology offers the possibility of joining structures with a wide range of material-geometry combinations. In order to realize the increasing number of varying products using different materials and designs within a process chain, they need to be versatile. Due to changing properties of the materials to be joined, tool geometries and process variables in mechanical joining processes, especially clinching, must be continuously adapted which results in a limited versatility of the process. In this regard, it is necessary to examine the robustness of the clinching process in versatile process chains. Therefore, a method is developed which describes the joint characteristics based on the material properties in order to enable the investigation of the clinching process regarding the robustness concerning continuously changing process and material conditions. The predictive accuracy of numerical simulations for mechanical joining processes depends on the implemented material model, especially the plasticity of the joining parts. Therefore, experimental material characterization processes are used to determine material properties. Furthermore, clinched joints in different material combinations are experimentally generated and examined. Based on these investigations a simulation model of the joining process is developed as 2D-Clinching FEM model in LS-Dyna. The Validation of the developed simulation model is ensured by comparing the geometric formation of the joint and force-displacement curves of the joining process with experimental generated joints. By combining the simulation model with an optimization tool (LS-OPT) the influence of different parameters on the joint characteristics is determined and the robustness of the joining process in versatile process chains is investigated.