Clinching Simulation III

White Paper
Maximizing the joint strength of a clinching process

using AFDEX and HyperStudy
Whitepaper Author
Renganathan Sekar
Executive Summary:
In order to determine optimum process parameters and conditions, the FE simulation models need to be integrated with
optimization algorithms. This is very important for metal forming processes as they are dependent on a number of process
parameters affecting the product quality and manufacturing efficiency. In this white paper, a suitable FE model of a joining
process(clinching) is built using the metal forming simulator AFDEX and then the process is optimized using the
multidisciplinary optimization software HyperStudy from Altair. Through the optimization approach, the process
parameters are optimized, and the joint strength is increased by about 36%.
Introduction:
The usage of aluminium alloys is pivotal in reducing the weight of an automobile. Conventional joining methods of
aluminium sheets such as the welding are not effective because of the formation of an oxide layer surface as well the high
thermal conductivity of the material. An economically feasible alternative to welding is the clinching process. Figure 1
shows the schematic of the clinching process. The two sheets are joined by applying a force through the punch resulting in
their plastic deformation.
Figure 1: Schematic of the clinching process [1]
AFDEX, an intelligent metal forming simulator developed by MFRC, is used to simulate a 2-stage forging process. Based on
the results of the initial design run, two die shape parameters in the process are optimized using Altair HyperStudy, the
multi-disciplinary design exploration and optimization software.
Altair Engineering, Inc., World Headquarters: 1820 E. Big Beaver Rd., Troy, MI 48083-2031 USA
Phone: +1.248.614.2400 • Fax: +1.248.614.2411 • altair.com • info@altair.com
Setup of the FE Model:
The actual clinching process consists of only one stage. For the sake of testing and improving the joint strength, a second
stage is included in this study. The first stage is where the actual deformation happens to clinch the two sheets together.
And the second stage consists of applying a tensile load that will pull the two clinched sheets apart. Higher this force,
greater is the joint strength. The joint strength, which is the tensile load or the second stage forming load will be used as
an objective function which ought to be maximized. Figure 2 has the simulation information and the deformed shape of
the workpieces after joining.
Figure 2: FE model of a clinching process in AFDEX and the simulation details
Setup of the optimization problem:

After carrying out an extensive literature survey, the design variables that significantly influence the joint strength of the
clinching process are chosen as shown in Figure 3.
Figure 3: Design variables of clinching process

HyperStudy is solver neutral and allows the realization of parameterization in various ways including from an excel
spreadsheet. It can integrate to any simulation software that has ASCII input files through template files [2]. Template files
(with extension ‘.tpl’) are parameterized versions of the simulation input files which usually depend on the solver which is
used for carrying out the nominal run. The input files of AFDEX are SIF and SCF which correspond to Simulation Input File
and Simulation Control File respectively. As the names suggest, SIF file contains information about workpiece and die
geometry, the input process parameters like friction, die velocity etc., and SCF consists of the factors that control the
simulation and it is subject to change during execution.
The above design variables are defined in HyperStudy using the SIF file of AFDEX. In the case of the second and third
design variables (Die radius and Die depth), the variables are defined using expressions as these are not a single
parameter. For example, the value of die depth is dependent on y-coordinate value of two points. So, in this case,
it will be entered as an expression whose value will be equal to the difference of the y-coordinate values.
Figure 4: Optimization of the design variables in HyperStudy
The forming load of the second stage is chosen as the objective function which ought to be maximized. The global
response surface method (GRSM) is chosen as the optimization method. This deterministic global search method generates
a set of designs for every iteration and these are solved in parallel. The response surface is nothing but an algebraic or
numeric expression describing the model’s response as a function of the design variables. Several evaluations are carried
out within the feasible design space and the optimized values of the design variables are presented in Figure 4.
Figure 5: Joint strength after optimization

The optimized(maximized) joint strength values are also plotted in Figure 5 with respect to the number of iterations. The
final optimized values of the design variables as well as the joining force is presented in Figure 6. It can be observed that
the strength of the joint has been increased by a significant 36.4% through this optimization process.
Figure 6: Optimization results
Conclusion:
The joining strength of the clinching process of two aluminium alloy sheets of 2.5 mm thickness was increased up to
36.4% using FEM and deterministic optimization approach in this work. This framework of using a FEM simulation tool and
an optimization algorithm is very general and versatile in nature. This increases the application spectrum of this technique
to a wide range of metal forming processes and their optimization.
References:
[1] C. J. Lee, J. Y. Kim, S. K. Lee, D. C. Ko, B. M. Kim, 2009, Design of mechanical clinching tools for joining of aluminium
alloy sheets, Materials and Design 31(2010), 1584-1861
[2] Varis J., Economics of clinched joint compared to riveted joint and example of applying calculations to a volume
product, J Mater Process Technol, 2006; 172: 130-8
Contact Information:
Renganathan Sekar (r.sekar@afdex.com), Associate Research Engineer, MFRC

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White Paper

Maximizing the joint strength of a clinching process

Figure 1: Schematic of the clinching process [1]

Figure 2: FE model of a clinching process in AFDEX and the simulation details

Setup of the optimization problem:

Figure 3: Design variables of clinching process

Figure 4: Optimization of the design variables in HyperStudy

Figure 5: Joint strength after optimization

Figure 6: Optimization results

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