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Effect of interlock angle and bottom die flange diameter on clinching joint load bearing capacity in cross-tensile loading

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Abstract

Clinching is a mechanical sheet metal joining technique, wherein the sheets are geometrically interlocked using a specially designed tool that does not require pre-hole or additional rivet material. In practical situations, the use of cross-tensile configuration is widespread, whose load-bearing capacity is found to be lower than that of lap shear configuration. Analytical models are easy to use and enable faster evaluation of joint strength. A novel analytical approach is proposed and validated experimentally. It is done on clinching joints made from Al 1100, because of low cost and good corrosion properties, sheets for various die flange diameters. Further, the experimental work carried out on various die flange diameters, varying from 0 to 12 mm at a step of 2 mm, showed that a different mode of failure could occur in which the interlock region fails by shear rather than button separation. The strength of joints in this proposed failure mode is consistent with the experimental data. The maximum strength of 2.15 kN was observed for a 6 mm diameter flange. Finite element simulations are performed to predict the occurrence of this mode of failure and its associated strength. Importantly, the critical interlock angle at which this mode of failure occurs is predicted. In the present study, this mode of failure is seen to occur when the angle of interlock exceeds 20°. The strength of the joints is higher during the button shear mode of failure when compared to the button separation mode. The critical angle thus commands the incurring mode of failure.

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Abbreviations

X:

Plate thickness between die and punch

Y:

Interlock length

tU :

Undercut

α:

Interlock angle

tN :

Neck thickness

Rp :

Punch radius

RC :

Punch corner radius

Rf :

Die flange radius

Rd :

Die radius

H:

Die depth

Fb :

Button strength

Fse :

Button separation strength

µ:

Coefficient of friction

σ:

Yield strength

Fn :

Neck strength

Fsh :

Button shear strength

τT :

Top shear strength

τB :

Bottom sheet base metal material

CoF:

Coefficient of friction

Vx :

Axisymmetric strained x-direction

FD:

Die flange diameter

αc :

Critical interlock angle

SFTC:

Scientific forming technologies and corporation

Fsh (T):

Button shear strength at the top

Fsh (B):

Button shear strength at the bottom

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Science, Bangalore, 560012, India

    Santosh Kumar

  2. Department of Mechanical Engineering, Nitte Meenakshi Institute of Technology, Bangalore, 560064, India

    Avinash Lakshmikanthan

  3. School of Science and Engineering, Curtin University, 345031, Dubai, UAE

    Chithirai Pon Selvan

  4. Department of Mechanical Engineering, KLS Gogte Institute of Technology, Belagavi, Karnataka, 590006, India

    Vinayak Malik

  5. Department of Mechanical Engineering, GLA University, Mathura, 281406, India

    Kuldeep K. Saxena

  6. Mechanical Engineering, UIET, Panjab University, Chandigarh, 160014, India

    Shankar Sehgal

  7. Department of Medical Physics, Hilla University College, Babylon, Iraq

    Kahtan A. Mohammed

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  1. Santosh Kumar
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Kumar, S., Lakshmikanthan, A., Selvan, C.P. et al. Effect of interlock angle and bottom die flange diameter on clinching joint load bearing capacity in cross-tensile loading. Int J Interact Des Manuf 17, 2209–2220 (2023). https://doi.org/10.1007/s12008-022-00955-5

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