Reproducing the experimental strength of clinched connections with finite element methods

Clinching is a joining technique in which two sheet metal parts are locally deformed so that they mechanically interlock. This is done with relatively simple tools that consist of a punch, a die and a blankholder. The geometry of the punch and die determine the final geometry of the clinch which in turn determines the strength of the connection. The optimal geometry for a certain application can be investigated with finite element simulations. For these results to be useful, they have to be able to reproduce the experimental strength of the connection, and it is here that many difficulties still exist. In this paper we show what these difficulties are and how they can be overcome in order to have a reliable simulation tool to predict the experimental strength of new types of connections.status: publishe