Ahmad Salleh Buang1, *, Mohd Rosli Rasidi2, Mohd Idris Shah Ismail3

 12Department of Mechanical Engineering, Polytechnic of Banting Selangor, Malaysia

3Deptment of Mechanical and Manufacturing Engineering Faculty of Engineering, University of Putra Malaysia  


The implementation of a novel clinching joining technology can result in decreased production costs and cycle times, while also providing potential opportunities for product design and manufacturing. This investigation aimed to experimentally and numerically examine the overlap joining process of low carbon steel and aluminum alloy using the clinching process. In the present study, the mechanical joint of the clinching process has been numerically investigated using the finite element (FE) method. To validate the numerical simulation of the clinching process, experimental tests on clinching for joining dissimilar materials have been carried out. The tensile-shear test was conducted to evaluate the strength of overlap-clinched joints in terms of their resistance to tensile-shear force. The test was additionally employed to examine how clinched joints undergo deformation and failure when subjected to tensile-shear loads. The findings indicated that applying a greater press load greatly impacted the improvement of interlocking between steel-aluminum hybrid structures. The failure of clinched joints occurred due to a lack of proper interlocking and a thin thickness of the neck. Furthermore, the area of utmost significance in the clinching tool was situated at the radius corner of the punch and die. The results obtained from experimental tests and simulation methods also show a similarity that can be adopted.


Clinching process; Hybrid structure; Interlocking;