FE modeling and simulation framework for the forming of hybrid metal-composites clinching joints

A 3D elasto-plastic numerical modeling and simulation framework is proposed for the forming of hybrid metal-composites clinching processes. The framework is employed in the commercial finite element software ABAQUS. The proposed FE procedures are presented and discussed in detail. Then, an experimental-numerical validation example of a metal-composites hybrid clinching process is presented. The material pairing of PA6GF30 and EN AW 5754 is chosen for this purpose. Accordingly, a user-defined constitutive model is employed for the PA6GF30 sheet to represent the sophisticated constitutive behavior of composites in more realistic manner. A brief description of the model and the parameter identification is provided. For the EN AW 5754 material, the standard von Mises model is used. The simulation results presented show the applicability and accuracy of the modeling framework, which can serve as a tool to investigate and to improve the mechanical behavior of hybrid clinching joints.