Journal of Materials Processing Technology 214 (2014) 2112–2118

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Journal of Materials Processing Technology

journal homepage: www.elsevier.com/locate/jmatprotec

Mechanical clinching of ultra-high strength steel sheets and strength

of joints
Yohei Abe a,∗ , Toru Kato b , Ken-ichiro Mori a , Shoma Nishino a
a
Department of Mechanical Engineering, Toyohashi University of Technology, Toyohashi, Aichi 441-8580, Japan
b
Department of Mechanical Engineering, Ishikawa National College of Technology, Ishikawa 929-0342, Japan

a r t i c l e i n f o a b s t r a c t

Article history: Ultra-high strength steel sheets having low ductility were joined by mechanical clinching with dies
Received 15 August 2013 for control of metal flow. The diameter and depth of the die were modified to relieve concentration of
Received in revised form 10 January 2014 deformation of the sheets for avoidance of the occurrence of sheet fracture. As the tensile strength of
Accepted 1 March 2014
the steel sheets increased, the interlock decreased due to small metal flow. Two kinds of the ultra-high
Available online 12 March 2014
strength steel sheets having different ductility were used. The ultra-high strength steel sheets having
large ductility were successfully joined using die having modified shape, whereas the sheets having
Keywords:
small ductility were not joined. The static and fatigue strengths of the mechanically clinched joint were
Joining
Mechanical clinching
compared with those of the resistance spot welded joint. Although the static load of the mechanically
Ultra-high strength steel sheet clinched joint was smaller than that of the resistance spot welded joint in both tension-shearing and
Fatigue strength cross-tension tests, the fatigue load of the clinched joint was larger in the large number of cycles. It was
Static strength found that mechanical clinching has superior fatigue strength due to the large yield stress of the sheets
Resistance spot welding and relaxation of the stress concentration.
© 2014 Published by Elsevier B.V.

1. Introduction galvanised steel sheets, the wear of welding electrode becomes

large due to the lower electrical resistance and melting tempera-
To reduce the weight of automobiles, the use of high strength ture of the coating layer. Zhang et al. (2008) reported that the wear
steel and aluminium alloy sheets tends to increase because of their of electrode tips for the galvanised high strength steel sheets was
high specific strength. For the reduction, mild steel automobile accelerated because of high strength of the sheets. Although Zou
parts tend to be replaced with high strength steel ones. Particu- et al. (2009) developed coating of electrodes to improve the life,
larly, ultra-high strength steel sheets having a tensile strength more the coating thickness of the galvanised steel sheet is decreased by
than 1 GPa are attractive for the reduction. The high strength and heating and high pressure during welding.
ultra-high strength steel parts are conventionally joined by resis- Mechanical clinching is a cold joining process of sheets by local
tance spot welding. For the automobile parts, not only the static hemming with a punch and die. The joining process is used in auto-
strength but also the fatigue strength is important. As the tensile mobile (Barnes and Pashby, 2000), building (Pedreschi and Sinha,
stress of steel sheets increases, the static load of the joint by resis- 2008), electrical industries. Krause and Chernenkoff (1995) showed
tance spot welding becomes large (Futamura and Miura, 2008), that the fatigue load of aluminium alloy sheets joined by mechani-
whereas the increase in fatigue strength of the joint is not large. In cal clinching was approximately 25% larger than that by resistance
the high strength steel sheets, particularly the ultra-high strength spot welding. Saathoff and Mallick (1998) reported that tool shapes
steel sheets, the initiation and propagation of cracks are sensitive in mechanical clinching affected fatigue strength of the clinched
(Fujii et al., 2011). It is desirable in automobile industry to develop joints of aluminium alloy sheets. Carboni et al. (2006) investigated
a joining process for attaining high fatigue strength of joints for the fracture behaviour and stress distribution in a tensile–shear fatigue
high strength steel sheets. test of clinched joints. Mori et al. (2007, 2012) clarified the mecha-
Galvanised steel sheets having corrosion resistance are use- nism of high fatigue strength for aluminium alloy sheets joined by
ful to improve life of automobiles. In resistance spot welding of mechanical clinching. The fatigue strength may be superior for not
only aluminium alloy sheets but also high strength steel sheets. On
the other hand, Varis (2006) reported that the mechanical clinching
∗ Corresponding author. Tel.: +81 532 44 6705; fax: +81 532 44 6690. has the advantage of low running costs without a rivet unlike self-
E-mail address: [email protected] (Y. Abe). pierce riveting. The corrosion resistance of galvanised steel sheets

http://dx.doi.org/10.1016/j.jmatprotec.2014.03.003
0924-0136/© 2014 Published by Elsevier B.V.
 Y. Abe et al. / Journal of Materials Processing Technology 214 (2014) 2112–2118 2113

(a) (b) Table 1

Punch Mechanical properties of 980 MPa ultra-high strength steel sheets.
Sheet holder
Sheet Thickness (mm) Tensile Reduction in
strength (MPa) area (%)

Upper sheet Non-coated (JSC980Y) 983 62

1.2
Galvanised (JAC980Y) 1009 43

Lower sheet
(b) Blankholder

Die Punch
(a) Large tmin Upper sheet

Small h
(c)
d Small x

h
Lower sheet Die

Minimum wall thickness tmin (c) (d)

Interlock x

Small tmin Large tmin

Fig. 1. Mechanical clinching for joining of sheets. (a) Initial, (b) flaring and (c) joining. Small x
Small x
joined by mechanical clinching was higher than that by welding Die
Small d Large d
(Abe et al., 2010).
Mechanical clinching of ultra-high strength steel sheets is not Fig. 2. Effects of depth and diameter of die on metal flow of sheets. (a) Depth h
easy. Although the high strength steel sheets were joined by and diameter d of die, (b) small die depth, (c) small die diameter and (d) large die
mechanical clinching (Varis, 2002, 2003), the fracture tends to diameter.
occur in joining of ultra-high strength steel sheets due to low duc-
tility. Neugebauer et al. (2008) developed a mechanical clinching have about 1000 MPa of tensile strength, the ductility of the gal-
process with heating dies, and then the magnesium alloy sheets vanised sheet JAC980Y (Japan Iron and Steel Federation) is lower
were successfully joined without fracture at high temperatures. than that of non-coated sheet JSC980Y (Japan Iron and Steel Feder-
However, heating of steel sheets at high temperature is not easy. By ation).
using dies for control of the metal flow, not only the mild steel and The effects of the depth h and diameter d of the die on metal flow
aluminium alloy sheets (Abe et al., 2007), but also the ultra-high of the sheets are illustrated in Fig. 2. As the die depth decreases, the
strength steel and aluminium alloy sheets (Abe et al., 2012a) were concentration of deformation around the punch corner is relieved,
joined. However, in joining of ultra-high strength steel sheets, the and thus the fracture of the upper sheet is prevented, the amount of
punch load becomes large due to high flow stress of the sheet (Abe interlock is not sufficient. On the other hand, the amount of inter-
et al., 2012b). lock is insufficient for excessively small and large diameter of the
In the present study, ultra-high strength steel sheets having low die.
ductility were joined by mechanical clinching with dies for control The tools used for an experiment of mechanical clinching of
of metal flow. A shape of the die was optimised to relieve concen- ultra-high strength steel sheets is illustrated in Fig. 3. To prevent
tration of deformation of the sheets. The static and fatigue strengths of the plastic deformation of the die, the die having diameter d and
of joints of mechanically clinched ultra-high strength steel sheets
were compared with those of resistance spot welded sheets.
100
Critical reduction in wall thickness of

2. Conditions of mechanical clinching

80
In mechanical clinching, the sheets are formed by the punch and
upper sheet [%]

die to generate the interlock x between the lower and the upper
60
sheets as shown in Fig. 1. The upper and lower sheets are joined by
being hooked on the interlock generated around the punch corners,
whereas the thickness of the upper sheets decreases around this 40 Non-coated
corner. The critical wall thickness of the upper sheet around the
punch corner without fracture is required. The fracture of the sheets Coated
20
brings about the corrosion of the parts. Appropriate strength of the
joint of the sheets is obtained from the interlock and minimum wall
thickness tmin . 0
The material properties of the ultra-high strength steel sheets 200 400 600 800 1000 1200
Tensile strength of steel sheets [MPa]
having a nominal tensile strength of 980 MPa used for mechanical
clinching are given in Table 1. The tensile strength and reduction Fig. 3. Tools used for experiment of mechanical clinching of ultra-high strength
area are measured from uniaxial tension test. Although both sheets steel sheets.
2114 Y. Abe et al. / Journal of Materials Processing Technology 214 (2014) 2112–2118

depth h was used although the die having space in the bottom cor-
ner was developed. The die was made of alloy tool steel SKD11. The Punch
effects of the die diameter d and the die depth h on the joinabil-
ity were investigated. The final punching load was fixed to 70 kN Blankholder
without plastic deformation of the punch. The punch was made of

1.2
5.2 Upper sheet
cemented carbide VM-50 (Japanese Cemented Carbide Tool Indus-
trial Standard) having high compressive strength.

1.2
Lower sheet
To evaluate the formability of the ultra-high strength steel sheet,
the critical reduction in wall thickness of the upper sheet around d Die

h
punch corner was measured. The relationship between the max-
imum reduction in wall thickness and the tensile strength of the
steel sheets for d = 8.0 mm is shown in Fig. 4, where 390, 590 and
Fig. 4. Relationship between critical reduction in wall thickness of the upper sheet
780 MPa sheets were mechanically clinched as a comparison (Abe around punch corner and tensile strength of steel sheets.
et al., 2010). The die has an enough depth to avoid the touch with
the lower sheet. As the tensile strength of steel sheets increases,
the maximum reduction in wall thickness decreases because of joined without defects. The interlock is not generated in the sheets
reduction in the ferrite in the dual-phase steel. Thus, the tool shape for h = 1.2 mm due to the small interlock. The upper sheet fractures
to relieve the concentration of sheet deformation is required for for h = 2.0 mm because the reduction in the wall thickness of upper
joining of the ultra-high strength steel sheets. sheets becomes large.
The deforming shapes of the sheets and the variations in the
maximum reduction in wall thickness around punch corner with
3. Joinability of 980 MPa steel sheets the punch stroke for d = 8.0 mm, h = 1.6 mm and the non-coated
sheet are shown in Fig. 6. The lower sheet was contacted the bottom
The cross-sectional shapes of the sheets for the non-coated sheet of the die cavity at 1.4 mm of punch stroke, and then the material
and d = 8.0 mm are illustrated in Fig. 5. For h = 1.6 mm, the sheets are between the punch and the bottom of the die cavity flows into the

Fig. 5. Cross-sectional shapes of sheets for non-coated sheet and d = 8.0 mm. (a) No defect, h = 1.6 mm; (b) no interlock, h = 1.2 mm; (c) upper sheet fracture, h = 2.0 mm.

Fig. 6. Deforming shapes of sheets and variations in maximum reduction in wall thickness around punch corner with punch stroke for d = 8.0 mm, h = 1.6 mm and non-steel
sheet.
 Y. Abe et al. / Journal of Materials Processing Technology 214 (2014) 2112–2118 2115

(a) 2.2 (b) 2.2

Upper sheet fracture
Die depth h [mm] 2.0 2.0
Upper sheet fracture

Die depth h [mm]

1.8 1.8

1.6 1.6
No defect
1.4 1.4
No interlock
1.2 1.2
No interlock
1.0 1.0
8.0 8.5 8.0 8.5
Die diameter d [mm] Die diameter d [mm]

Fig. 7. Joining ranges; (a) non-coated sheet; (b) galvanised sheet.

die corner. The maximum reduction is increasing to 2 mm of punch

stroke, then the reduction is constant to the final punch stroke.
Although the maximum reduction reaches the critical reduction
at the final stroke, the fracture was prevented due to metal flow Fig. 9. Effect of tensile strength of sheet on interlock and minimum wall thickness
between punch and die corners. of upper sheet.
The joining ranges for the non-coated sheet and galvanised steel
sheet are shown in Fig. 7. The non-coated sheets were joined in increases, and then the interlock decreases due to small metal flow
appropriate die shape. In the large die depth, the fracture in the as the tensile strength of the sheet increases. The interlock for
upper sheet is observed. In the small die depth, the amount of inter- 980 MPa steel sheet is slightly larger than that of 780 MPa steel
lock is not sufficient due to small die cavity. The galvanised sheets sheet because of the large die depth.
were not joined because of low ductility of the sheet in Table 1. The joint load of mechanical clinching was compared with that
The interlock and minimum wall thickness of the upper sheet of the resistance spot welding. The conditions of resistance spot
of the joined sheets for non-coated sheet are shown in Fig. 8. As welding and the diameter of weld nugget are shown in Table 3.
the die depth decreases, the concentration of deformation becomes The strength of the joined sheets was measured from the
small, whereas the interlock between the upper and lower sheets tension–shearing and cross-tension tests. The measuring condi-
decreases due to the small metal flow between corners of the punch tion was chosen on the basis of the Japanese Industrial Standard
and die. The die having d = 8.0 mm and h = 1.6 mm is selected for the Committee. The load–stroke curves of the joints measured from
non-coated sheet because of the larger interlock. the tension–shearing test for the non-coated sheet are shown
in Fig. 10. The maximum load for mechanical clinching was
4. Static and fatigue strengths of joints 4.4 kN, 36% of that for resistance spot welding. In the mechan-
ical clinching, the sheets were joined by being hooked on the
4.1. Static strength interlock generated by plastic deformation, and then the upper
sheet was pulled from lower sheet by the rotation of the joint.
To show the effect of strength of steel sheets on the joint load, In resistance spot welding, the fracture occurred in the weld
from the 370 MPa to 780 MPa of high strength steel sheets were nugget.
used. Nominal thickness for all materials were 1.2 mm. The 590 MPa The load–stroke curves of the joints measured from the cross-
(MSM-C K590, code of Nisshin steel) and 370 MPa (MSM-C K370, tension test for the non-coated sheet are shown in Fig. 11. The joint
code of Nisshin steel) steel sheets were Zn–Al–Mg-alloy-coated load of mechanical clinching was 2.8 kN, and then 56% of that of
ones having high corrosion resistance. The 780 MPa sheet was resistance spot welding. The separation behaviour of the mechani-
galvanised-steel sheet. The mechanical properties and geometri- cal clinched sheets was same with that of the tension–shearing test.
cal properties of die for joining of high strength sheets are shown In resistance spot welding, the fracture occurred around the weld
in Table 2. The upper and lower sheets were same material. nugget.
The effect of the tensile strength of the sheet on the interlock The effect of the tensile strength of the steel sheets on the max-
and minimum wall thickness of the upper sheet is shown in Fig. 9. imum load of joints is shown in Fig. 12. The joint loads of resistance
To join sheets without the fracture, the minimum wall thickness spot welding were larger than those of mechanical clinching in both
tension–shearing and cross-tension tests. In the cross-tension test
0.5 0.5 of 780 MPa and 980 MPa steel sheets, the difference load between
Minimum wall thickness the resistance spot welded and mechanically clinched joints was
Minimum wall thickness of

0.4 d =8.0mm 0.4 small.

upper sheet [mm]

d =8.5mm
Interlock [mm]

0.3 0.3 4.2. Fatigue strength

0.2 0.2
Fatigue loads of the joints by mechanical clinching and resis-
tance spot welding for non-coated sheet were measured. Each
0.1 Interlock d =8.0mm 0.1
d =8.5mm test was ended when the displacement became excessive. In
0 0 the fatigue test, the repeated load cycle between tension and
1.2 1.4 1.6 1.8 unloading was employed under a frequency between 5 and
Die depth h [mm]
30 Hz.
Fig. 8. Effect of die shape on interlock and minimum wall thickness of upper sheet
The relationship between the load and number of cycles
for non-coated sheet. is shown in Fig. 13. As the number of cycles increases, the
2116 Y. Abe et al. / Journal of Materials Processing Technology 214 (2014) 2112–2118

Table 2
Mechanical properties and geometrical properties of die for joining of high strength sheets.

Sheet Tensile Reduction Coating Diameter of die Depth of

strength (MPa) in area (%) d (mm) die h (mm)

Non-coated 983 62 Non 8.0 1.6

780 MPa (JAC780) 811 48 Zn–Fe 8.5 1.5
590 MPa (MSM-C K590) 606 50 Zn–Al–Mg alloy 8.5 1.8
370 MPa (MSM-C K370) 377 67 Zn–Al–Mg alloy 8.5 2.0

Table 3
Conditions of resistance spot welding and diameter of weld nugget.

Sheet Diameter of copper Welding current (kA) Welding pressure (MPa) Welding time (s) Diameter of weld
electrodes (mm) nugget (mm)

Non-coated 7.0 9.8 0.20 0.2 5.9

780 MPa 7.0 9.8 0.20 0.2 6.0
590 MPa 8.0 9.8 0.15 0.4 6.5
370 MPa 8.0 9.8 0.15 0.4 6.1

Fig. 10. Load–stroke curves measured from tension–shearing test for non-coated sheet; (a) load-stroke curves; (b) fractured sheets.

load amplitude decreases. The load amplitude of mechani-

cal clinching at 107 of number of cycles was 2.0 kN in the
tension–shearing test, and then 2.5 times of that of resistance
spot welding. In mechanical clinching, the minimum thickness
potion in the upper sheet fractured. In resistance spot welding,
the fracture occurred around the weld nugget. Although the load
amplitude for the cross-tension test is smaller than that in the
tension–shearing, the tendency of the load amplitude and the
fracture behaviour are similar to the tension–shearing test. It was
found that the mechanically clinched joint had a superior fatigue
loads.
The distribution of Vickers hardness in the joined upper sheet
by mechanical clinching for non-coated sheet is shown in Fig. 14.
The hardness of the mechanically clinched joint was increased by
the work-hardening for large plastic deformation.
The distribution of Vickers hardness in the joined sheets
by resistance spot welding for the non-coated sheet is shown
in Fig. 15. Although the weld nugget has large hardness, the
edge of weld nugget is softened by annealing in resistance spot
welding.
The yield stress of the mechanically clinched sheets is increased
Fig. 11. Load–stroke curves measured from cross-tension test for non-coated sheet;
by the work-hardening undergone during the joining processes
(a) load-stroke curves; (b) fractured sheets.
 Y. Abe et al. / Journal of Materials Processing Technology 214 (2014) 2112–2118 2117

14
(a)
12 Vickers hardness [HV0.2]
Resistance spot welding 440
Maximum load [kN]

10
400
Upper sheet
8 360
340
6
Lower sheet
4
Mechnicalclinching Fig. 14. Distribution of Vickers hardness in joined upper sheet by mechanical clinch-
2 ing for non-coated sheet.

0
200 400 600 800 1000 1200
Edge of weld nugget Vickers hardness [HV0.2]
Tensile strengthof steel sheets[MPa] 440
(b) 400
8 Resistance spot welding 360
Maximum load [kN]

6 340
320
4
Mechnicalclinching 280
2
Fig. 15. Distribution of Vickers hardness in joined sheets by resistance spot welding
0 for non-coated sheet.
200 400 600 800 1000 1200
Tensile strengthof steel sheets[MPa]
(a) (b)
Fig. 12. Effect of tensile strength of sheet on maximum load of joins; (a) Complete bonding 400HV0.2
tension–shearing test; (b) cross-tension test.
Stress Slight slip
290HV0.2 concentration
Relaxation of stress
in Fig. 14, whereas the yield stress for resistance spot welding is
reversely decreased by annealing in welding in Fig. 15. Mori et al. Fig. 16. Deforming behaviour of joints by resistance spot welding and mechanical
(2007, 2012) showed that the stress concentrates at the edge of the clinching in the fatigue test; (a) resistance spot welding; (b) mechanical clinching.
weld nugget due to the complete bonding in the resistance spot
welding in the fatigue test, whereas the concentration of stress is
relaxed by the slight slip at the interface between the sheets for 5. Conclusions
mechanical clinching of aluminium alloy sheets. It is possible that
the tendency of the stress concentrations for the ultra-high strength To join the ultra-high strength steel sheets having a low duc-
steel sheets is similar to that for the aluminium alloy sheets, thus tility by mechanical clinching, the diameter and depth of the die
mechanical clinching has superior fatigue load due to the large yield were modified. The effect of the tensile stress of the steel sheets on
stress of the sheets and relaxation of the stress concentration as the joinability was investigated. In addition, the static and fatigue
shown in Fig. 16. strengths of mechanically clinched and resistance spot welded

Fig. 13. Relationship between load amplitude and number of cycles for non-coated sheet; (a) tension-shearing test; (b) cross-tension test.
2118 Y. Abe et al. / Journal of Materials Processing Technology 214 (2014) 2112–2118

joints in ultra-high strength steel sheets were measured. The fol- Carboni, M., Beretta, S., Monno, M., 2006. Fatigue behaviour of tensile-shear loaded
lowing results were obtained: clinched joints. Eng. Frac. Mech. 73, 178–190.
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