Increasing the accuracy of clinching process simulations by modeling the friction as a function of local joining process parameters

In this study, an innovative friction model is used to improve the quality of clinching process simulations. Consequently, the future over dimensioning can be reduced. Furthermore, the improved prediction quality of the joining process simulation leads to an improvement in the simulation of load-bearing capacity as well. In this way, the entire sampling process can be performed virtually without any experimental investigations. This will contribute to the advancement of lightweight construction in the automotive industry. In this work, the frictional behavior is studied in dependence on the local joining process parameters. As a reference for the numerical investigations, clinch joints by means of a die with fixed geometry are joined. Additionally, a hardness mapping is performed on the microsection of the clinch joints. It shows the local strain hardening, which correlates with the forming degree in the simulation. Based on the occurring contacts and the local joining process parameters in the joining process simulation, the test matrix for the experimental friction tests is defined. The friction tests are carried out on a compression-torsion-tribometer. This type of tribometer is able to apply high interface pressures above the initial yield stress due to the specimen encapsulation. Besides, the pure joining part contact, the contact between the joining part and joining tool can be tested as well. The experimental test setup offers the possibility to evaluate the influences of temperature, relative velocity, interface pressure, and frictional stroke independently. Based on the results of the experimental friction tests, a friction model is created. The resulting friction model is integrated into the numerical joining process simulation via a subroutine. To validate the quality of the new friction modeling, the results of simulations are compared with the experiments in terms of load-stroke diagrams, joint geometry, and hardness mappings on the microsection. </jats:p>