Effect of forming parameters on the mechanical properties of clinched joint with rectangle punch

The emergence of advanced lightweight materials has not only provided more options for industrial lightweighting, but also imposes higher demands on joining technologies. The clinching process with rectangle punch (CRP) performs well in joining steel or other materials with poor plasticity. In the present paper, AA5182-O sheets were chosen as the research material. The microscopic mechanisms involved in the creation of clinched joints through CRP were examined. An in-depth investigation into the influence of varying forming force, forming speed, and punching angle on the shear strength and failure modes of these joints was conducted. In conclusion, enhancing the forming force positively impacts the shear strength. The failure mode transitions from the separation failure mode to the neck fracture mode. At a forming force of 35 kN, the peak shear strength achieved was 2324 N. The forming speed exhibited minimal influence on the failure mechanism. The orientation of the joint's longer side relative to the shear force direction significantly affects the failure mechanism, when positioned perpendicularly, the shear strength reached the maximum, which was approximately 1.68 times greater compared to a parallel orientation. During the failure process, the interlocking region was subjected to shear force before the neck region and fractured first.