FEA-based optimisation of a clinching process with an open multiple-part die aimed at damage minimisation in CR240BH-AlSi10MnMg joints

Abstract

The paper presents results of a FEA-based tool design optimisation for a clinching process with an open multiple-part die. The studied materials are the bake-hardening steel CR240BH (1.5 mm) on the punch side and the die-cast aluminium alloy AlSi10MnMg (2.95 mm) on the die side. The objective of the optimisation was to minimise probability of cracks that appear at the outer circumference of the bottom of the clinch joint in AlSi10MnMg. In the framework of the optimisation, it was possible to minimise crack probability by varying geometrical parameters of the tools though at the cost of slightly worse but still tolerable geometrical parameters of the clinch joint.