A method for three-dimensional modelling of the shear-clinching process

<jats:p>Three-dimensional modelling enables to determine the in-plane material flow in asymmetrical situation. Thus, the distortion of the sheets to be joined can be characterized more exactly. This study shows a method for building up a three-dimensional shear-clinching framework without damage criteria. In fact, the die-sided sheet in shear-clinching was designed as a pre-punched sheet and slugs. The material separation in the die-sided joining partner, which in two-dimensional simulation is often described by macro- and micromechanical fracture criteria, was realised in this study based on a defined contact condition. By means of a shear-cutting simulation, a correlation between the break angle and the separation stress was determined, which was used as a separation criterion in the shear-clinching simulation. The separation line was confirmed using post-particles. To validate this model, the results of the simulation using a quadratic single-point specimen were compared to the experiments with respect to the distortion of the joining partner. In general, the built three-dimensional framework provides for further tool developments with regard to the reduction of distortion in shear-clinching.</jats:p>