Numerical simulation of the hybrid flat-clinching


  • Rym Boulanouar
  • Ali Benzegaou
  • Benabderrahmane Brani



mechanical joining, flat clinching, finite element method, hybrid joining, tensile test


The significance of mechanical joining continues to grow across various industrial sectors, including automotive and aerospace, Various processes, from traditional bolting and riveting to advanced techniques like welding, bonding and clinching, are used to assemble parts into a unified whole. One distinctive process is flat-clinching, particularly useful for joining two sheets by creating a geometrically interlocked joint, with its ability to create sturdy connections without the need for external elements, this process involves a punch pushing the sheets into a flat die, inducing local plastic deformation. Its advantages make it a valuable option in manufacturing. In this study, a numerical analysis using the finite element method was conducted, investigating the influence of several parameters as friction by taking many values, tool geometry by creating a new design and hybridization of materials on the flat clinching process. The focus was on evaluating the performance of joints formed by using three configuration of tool geometry by adding a shoulder on the holder and on the punch. lightweight materials, particularly Aluminum5754. Other commonly used materials were also considered as ETP copper, Brass CuZn37 and Mild steel, subjected to a tensile test for a comprehensive assessment. The findings offered understanding of how to enhance the flat-clinching process with regards to various materials depending on chosen parameters to maximize joint strength and reliability. Knowledge of these factors is important to manufacturers seeking to enhance productivity and performance of their products. In sum, this research adds to the general understanding of the mechanical joining methods and provides useful recommendations for companies that maybe interested in applying and optimizing flat-clinching for their joining tasks.


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How to Cite

Boulanouar, R., Benzegaou, A., & Brani, B. (2024). Numerical simulation of the hybrid flat-clinching. STUDIES IN ENGINEERING AND EXACT SCIENCES, 5(1), 2973–2998.