Numerical Investigation of the Coupled Friction Behavior in the Clinching Process Chain

The automotive industry achieves lightweight designs through the use of multi-material designs, which present challenges in joining and have led to an increased use of mechanical joining techniques. Clinching, as a mechanical joining process, has become a common technique in many areas of the automotive industry. To predict the relevant properties of clinched joints, the entire process chain is numerically simulated during the product development process. The accuracy of the predicted results strongly depends on the implemented friction model. The process chain of clinching is modeled in a finite element simulation, which represents different process steps such as joining and shear tensile loading. By coupling these different process steps, relevant values from the joining process can be transferred to the loading simulation. Using a friction subroutine, contact-relevant variables can be calculated along the process chain, and their influence on individual steps can be investigated. The aim of the study is to demonstrate the development of locally different friction-relevant parameters (such as friction displacement) along the clinching process chain.