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Multiscale Analogue Modelling of Clinching Process to Investigate Thickness Tolerance and Tool Misalignment
Sia A Nourani1, Dirk J Pons1, Digby Symons1
1Department of Mechanical Engineering, University of Canterbury, Christchurch 8140, New Zealand.
Materials (Basel, Switzerland)
|May 28, 2022
Summary
Dimensional variability significantly impacts clinching, with thickness tolerance and tool misalignment reducing interlock by half. Analogue modeling effectively studies these effects on clinch joints.
Area of Science:
- Manufacturing Engineering
- Materials Science
Background:
- The influence of sheet thickness tolerance and tool misalignment on clinching is not well understood.
- Finite element analysis (FEA) is computationally intensive and difficult to validate for clinching due to complex geometry and material behavior.
Purpose of the Study:
- To investigate the effects of thickness tolerance, tool misalignment, and sheet placement on the clinching process.
- To evaluate the efficacy of analogue modeling for studying clinching process variability.
Main Methods:
- Utilized a scaled-up punch and die with plasticine as an analogue material.
- Simulated thickness tolerances using varying plasticine sheet thicknesses and introduced angular variability.
- Tested glycerine and silicone oil as lubricants and measured interlock and neck thickness.
Main Results:
- Analogue modeling proved effective for studying dimensional deviations in clinch joints.
- Thickness tolerance critically reduced interlock by approximately 50% under maximum and least material conditions.
- Increased angular misalignment and the use of silicone oil (lower friction) also decreased interlock.
Conclusions:
- Analogue modeling is a valuable tool for exploring process variability in clinching.
- Sheet placement, lubricant type, sample thickness, and tool misalignment significantly affect clinching outcomes.
