FEM Simulation of Lap Shear Strength of Clinched Joints

Tensile-shear test was carried out for clinched joint, and finite element model was establishes to simulate the tensile shear process and the failure mode, and lap shear strength prediction formula was presented. The results show finite element model, which was established by shape, size of section of clinched joint and considering the contact conditions and friction between materials and friction, could be used to predict the lap shear strength and failure mode of clinched joint. Failure occured in the upper sheet with the minimum thickness for Al-Al and steel-steel clinched joints in the tensile-shear tests. Strength formula for joint strength could be used to predict the lap shear strength of clinched joint with the error of 4.6% for Al-Al clinched joint and 5.8% for steel-steel clinched joint. The lap shear strength mainly depended on the punch radius, shear strength of upper sheet and the neck-thickness.