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

Kumar, S and Lakshmikanthan, A and Selvan, CP and Malik, V and Saxena, KK and Sehgal, S and Mohammed, KA (2022) Effect of interlock angle and bottom die flange diameter on clinching joint load bearing capacity in cross-tensile loading. In: International Journal on Interactive Design and Manufacturing .

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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.

Item Type:	Journal Article
Publication:	International Journal on Interactive Design and Manufacturing
Publisher:	Springer-Verlag Italia s.r.l.
Additional Information:	The copyright for this article belongs to the Springer-Verlag Italia s.r.l.
Keywords:	Aluminum alloys; Aluminum corrosion; Bearing capacity; Bearings (machine parts); Corrosive effects; Joining; Loads (forces); Sheet metal; Tensile stress, Clinching joint; Cross-tensile load-bearing capacity; Interlock angles; Joint loads; Load-bearing capacity; Mechanical sheet joining and strength prediction; Mechanical sheets; Mode of failures; Strength prediction; Tensile loads, Flanges
Department/Centre:	Division of Mechanical Sciences > Mechanical Engineering
Date Deposited:	20 Jul 2022 12:27
Last Modified:	20 Jul 2022 12:27
URI:	https://eprints.iisc.ac.in/id/eprint/74958

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