Finite Element Analysis of Material Flow in Mechanical Clinching with Extensible Dies

An investigation of the material flow during the clinching process with extensible dies is carried out. Clinched joints were produced under different forming loads to evaluate the evolution of the joints’ profile experimentally. Tensile-shear tests were conducted to evaluate the influence of the forming load on mechanical strength of the clinched joint. Since the joints’ strength depends on the joints’ profile, which in turn depends on the punch-die cavity volume, an analysis of the forces acting on the extensible dies was carried out. A finite element model was developed and validated by comparing the predicted and measured material flow and quality criteria (e.g., neck thickness and undercut). Therefore, the FE model was utilized to analyze the evolution of contact forces acting on the die sectors during the joining process. Furthermore, the main causes of the asymmetry in the cross section of such joints have been studied. It turned out that the axial asymmetry due to material flow within the gap between consecutive die sectors increases with the punch force and the sheet thickness.