Finite element simulations of the clinch joining of metallic sheets

The joining method by clinching was simulated utilizing a finite element analysis (FEA) for various punch and die geometries. The simulations covered the effect of these changes on the joint undercut and neck thickness. The relevant geometrical aspects of the punch/die set were determined. The joint separation by applying normal forces to the sheets was also simulated; since this simulation involves some sheet bending, a new method for the evaluation of the separation force was simulated, eliminating the sheet bending during detaching. The importance of an adequate undercut on the joint strength was confirmed.