Investigation of the Clinching Process Under Variable Forming Speeds Using Finite Element Modelling and Post-Joint Extraction Analysis

Abstract

This study investigates the clinching joining process at different forming speeds using Finite Element Method (FEM) simulations. The objective is to analyze how process velocity influences material flow, stress distribution, deformation behavior, and final joint geometry. A numerical model was developed to replicate the clinching process, enabling the extraction of relevant mechanical characteristics such as local strain accumulation, contact pressure profiles, and residual stress fields in the joint region. The resulting clinched connections were further subjected to a simulated pull-out test to evaluate joint strength and separation behavior. Force–displacement curves were generated to quantify the extraction forces under different joining conditions, with particular attention to peak force levels and the onset of structural failure mechanisms. The data obtained provide insight into the correlation between forming speed and structural integrity of clinched joints. The outcomes of the research contribute to a deeper understanding of process parameters governing clinching, facilitating improved design and optimization of mechanically formed joints in thin-sheet applications.