The forming mechanism of clinch joints, for various materials arrangement, using a punch and a rigid die, is well known. The basic technological parameter of the process is the parameter X – the minimal thickness of the embossment. Usually, the lower the X parameter, the greater the joint interlock. This paper presents the possibility of forming a pressed joint for two 1.5 [mm] thick sheets made of HX340 steel. The joint was formed using an additional deformable steel rivet with a hardness of 400HV1. Different values of rivet pressing below the initial surface of the upper sheet were chosen: 0, 0.15, 0.30, 0.45 and 0.60 (in [mm]). The punch positioning accuracy was 0.01 [mm]. For the mentioned rivet pressing distances, forming tests were performed using an ‘‘SKB’’ die with three die depths: 1.45, 1.60 and 1.75 (in [mm]). Observations and measurements of the characteristic geometric dimensions of the interlock were made. Furthermore, the strength of the clinch-riveted joints was analysed. The greater the rivet pressing distance, the larger the interlock parameters. Furthermore, depending on the size of the rivet pressing distance, different failure mechanisms of the lap joint were observed in the tensile shear tests.

Clinching is a manufacturing method of mechanical joining two or more materials without the use of heat or additional components. This process relies on high plastic deformation to create a secure bond. Clinching technology is widely used for joining various grades and thickness of materials. Especially in the automotive industry, clinching is an alternative to spot resistance welding. However, the load-bearing capacity of clinched joints is comparatively lower when compared to resistance spot welded joints. This research aimed to enhance the load-carrying capacity of clinched joints. Experimental tests were conducted on clinched joints with locally modified microstructures to optimize their placement within the joint. The microstructure distribution in the clinched joint region was analysed using light and scanning electron microscopy, as well as microhardness measurements. Two material grades, micro-alloyed steels HX420LAD+Z and dual-phase ferritic-martensitic steels HCT600X+Z, were tested. Each grade underwent five groups of ten samples, subject to identical experimental conditions of local heating by resistance spot welding (RSW) and clinching. The application of RSW to the clinched joint area resulted in increase of load-bearing capacity for both joined types of materials.

This paper presents the deformation of the joined sheet after the clinch-riveting process. The DX51D steel sheet with zinc coating was used. The samples to be joined with clinch riveting technology had a thickness of 1±0.05 mm and 1.5±0.1 mm. The sheet deformation was measured before and after the joining process. The rivet was pressed in the sheets with the same dimension between the rivet axis and three sheet edges: 20, 30 and 40 mm. For fixed segments of the die, from the rivet side close to the rivet, the sheet deformation was greater than that of the area with movable segments. The movement of die sliding element caused more sheet material to flow in the space between the fixed part of the die and movable segments. Hence, the sheet deformation in these places was smaller than for the die fixed element – sheet material was less compressed. For sheets thickness 1.5 mm and width 20 mm, the bulk of the sheet was observed. For a sheets width of 20 mm, it was observed that the deformation of the upper and lower sheets in the area of the rivet is greater than for sheets width of 30 or 40 mm.