On the parametrical study of clinch joining of metallic sheets using the Taguchi method

The focus of this paper is the parametrical study of the clinch forming process. The tools geometry is crucial since the clinch joint resistance is found to be closely related with its final shape. The determination of the clinch joint resistance as a function of punch and die geometries is not described by any standards and must be determined by specific studies. In this paper, the Taguchi's design of experiments method is used to investigate the effects of tools geometry on the clinch joint resistance, as well as on its shape (nick thickness, clinch lock). ABAQUS/Explicit is used as the FEM analysis Software. The numerical simulations include the joint separation, by loading the sheets vertically, in order to evaluate the joint resistance to tensile loading. The relevant geometrical parameters of the tools are clearly identified. The results show the potential interest of the study and some issues for optimizing the tools geometry are outlined. (C) 2007 Elsevier Ltd. All rights reserved.