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Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions

Joining of materials, either with common or dissimilar mechanical properties or with different sheet thicknesses, is a frequently occurring task in the automotive industry. Mechanical clinching provides several major advantages compared to other joining techniques, such as resistance spot welding or self-piercing riveting, including low energy consumption and potential for lightweight automotive body construction.  The totality of the joints, i. e. spatial distribution and number of joints, is referred to as the joint layout. The sheet geometry and the cyclically applied forces govern the loading condition in each joint, resulting in pure shear, pull out or a mixed mode loading.

The material under investigation is the aluminum alloy EN AW-5182, which is widely used in the…

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Joining of materials, either with common or dissimilar mechanical properties or with different sheet thicknesses, is a frequently occurring task in the automotive industry. Mechanical clinching provides several major advantages compared to other joining techniques, such as resistance spot welding or self-piercing riveting, including low energy consumption and potential for lightweight automotive body construction.  The totality of the joints, i. e. spatial distribution and number of joints, is referred to as the joint layout. The sheet geometry and the cyclically applied forces govern the loading condition in each joint, resulting in pure shear, pull out or a mixed mode loading.

The material under investigation is the aluminum alloy EN AW-5182, which is widely used in the automotive industry, with a sheet thickness of 1.5 mm. The material behavior as input for the process simulation of mechanical clinching is determined in quasi-static tension according to DIN ISO 6892-1 [1]. The cyclic material properties are obtained through constant strain amplitude testing in compliance with SEP 1240 [2]. For a wide range of computationally created clinched joints the fatigue life estimation for different loading conditions, is carried out based on the algorithms described in the German FKM Guideline nonlinear [3] and previously reported in the case of shear loading [4]. The estimated fatigue life up to technical crack initiation is compared to experimentally obtained fatigue life data for different clinched joint geometries and in varying loading conditions. Special attention is paid to clinched joints under variable amplitude loading.

From the extensive numerical investigation of fatigue life up to crack initiation, verified by experimental fatigue testing, conclusions are drown on the applicability of the Local Strain Approach to clinched joints made of aluminum in different loading conditions. Furthermore, an approach is presented to link the geometrical features of the clinched joints, e. g. neck thickness and undercut, to the fatigue life.

Artikelnummer
VAL5-2024-046

Titel
Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions
Autor(en)
B. Spak, M. Schlicht, P. Froitzheim, W. Flügge, M. Kästner
DOI
10.48447/VAL5-2024-046
Veranstaltung
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
Jahr der Veröffentlichung
2024
Publikationsart
Tagungsmanuskript (PDF)
Sprache
Englisch
Stichwörter
Clinching,mechanical joining,Local Strain Approach,fatigue,variable amplitude loading

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Fatigue Crack Growth in 7075-T6 Aluminum Alloy under Single-Spike Overloads and Aircraft Spectra
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K. F. Walker, J. C. Newman
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A fatigue damage assessment approach in vibration fatigue exploiting the static approach
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1
Fatigue strength assessment of tube-to-flange welded steel joints with reinforcement ribs under variable amplitude loadings according to the Peak Stress Method
Fatigue strength assessment of tube-to-flange welded steel joints with reinforcement ribs under variable amplitude loadings according to the Peak Stress Method
A. Visentin, A. Campagnolo, V. Babini, G. Meneghetti
10.48447/VAL5-2024-052
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Steel welded joints,Variable Amplitude loads,Fatigue testing,Peak Stress Method,Automated fatigue strength assessment 
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Fatigue strength assessment of tube-to-flange welded steel joints with reinforcement ribs under variable amplitude loadings according to the Peak Stress Method
A. Visentin, A. Campagnolo, V. Babini, G. Meneghetti
10.48447/VAL5-2024-052
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Steel welded joints,Variable Amplitude loads,Fatigue testing,Peak Stress Method,Automated fatigue strength assessment
Preis 25,00 €
Nur online erhältlich
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
Autor(en): P. Schwarz, P. Häfele, T. Langlois
10.48447/VAL5-2024-026
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum 
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1
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
P. Schwarz, P. Häfele, T. Langlois
10.48447/VAL5-2024-026
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum 
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1
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
P. Schwarz, P. Häfele, T. Langlois
10.48447/VAL5-2024-026
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum
Preis 25,00 €
Nur online erhältlich
Fatigue life estimation of notched components under multiaxial non-proportional loading with variable amplitudes.
Autor(en): J. Kraft, M. Vormwald
10.48447/VAL5-2024-035
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
multiaxial fatigue,critical plane,notches 
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1
Fatigue life estimation of notched components under multiaxial non-proportional loading with variable amplitudes.
Fatigue life estimation of notched components under multiaxial non-proportional loading with variable amplitudes.
J. Kraft, M. Vormwald
10.48447/VAL5-2024-035
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
multiaxial fatigue,critical plane,notches 
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1
Fatigue life estimation of notched components under multiaxial non-proportional loading with variable amplitudes.
J. Kraft, M. Vormwald
10.48447/VAL5-2024-035
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
multiaxial fatigue,critical plane,notches
Preis 25,00 €
Nur online erhältlich
Dynamic fatigue analysis of a welded joints under sequential and simultaneous multi-axial random PSD loading
Autor(en): A. Halfpenny, S. Vervoort
10.48447/VAL5-2024-027
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Fatigue,vibration,multiaxial,spot weld,battery pack 
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1
Dynamic fatigue analysis of a welded joints under sequential and simultaneous multi-axial random PSD loading
Dynamic fatigue analysis of a welded joints under sequential and simultaneous multi-axial random PSD loading
A. Halfpenny, S. Vervoort
10.48447/VAL5-2024-027
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Fatigue,vibration,multiaxial,spot weld,battery pack 
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1
Dynamic fatigue analysis of a welded joints under sequential and simultaneous multi-axial random PSD loading
A. Halfpenny, S. Vervoort
10.48447/VAL5-2024-027
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Fatigue,vibration,multiaxial,spot weld,battery pack
Preis 25,00 €
Nur online erhältlich
Statistical method and associated non-linear cumulative model for fatigue nuclear applications
Autor(en): T. Lecleve, S. Courtin, F. Szmytka, C. Mai
10.48447/VAL5-2024-036
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Nuclear industry,Probabilistic models and methods,Amplitude-dependant models,Nonlinear cumulative damage 
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Statistical method and associated non-linear cumulative model for fatigue nuclear applications
Statistical method and associated non-linear cumulative model for fatigue nuclear applications
T. Lecleve, S. Courtin, F. Szmytka, C. Mai
10.48447/VAL5-2024-036
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Nuclear industry,Probabilistic models and methods,Amplitude-dependant models,Nonlinear cumulative damage 
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Statistical method and associated non-linear cumulative model for fatigue nuclear applications
T. Lecleve, S. Courtin, F. Szmytka, C. Mai
10.48447/VAL5-2024-036
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Nuclear industry,Probabilistic models and methods,Amplitude-dependant models,Nonlinear cumulative damage
Preis 25,00 €
Nur online erhältlich
Service strength assessment of macroscopic imperfections in cast steel alloys
Autor(en): M. Stoschka, M. Horvath, W. Mössler, F. Grün
10.48447/VAL5-2024-044
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Local fatigue assessment,Total strain energy density,Cast steel,Macroscopic shrinkage defects,Service strength 
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Service strength assessment of macroscopic imperfections in cast steel alloys
Service strength assessment of macroscopic imperfections in cast steel alloys
M. Stoschka, M. Horvath, W. Mössler, F. Grün
10.48447/VAL5-2024-044
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Service strength assessment of macroscopic imperfections in cast steel alloys
M. Stoschka, M. Horvath, W. Mössler, F. Grün
10.48447/VAL5-2024-044
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Local fatigue assessment,Total strain energy density,Cast steel,Macroscopic shrinkage defects,Service strength
Preis 25,00 €
Nur online erhältlich
Fatigue analysis of random variable loads acting on wheels for special off-highway applications from experimental data
Autor(en): L. Solazzi, A. Mazzoni, N. Danzi, M. Cima
10.48447/VAL5-2024-022
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
random fatigue,damage counting,wheel,stress acquisition 
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Fatigue analysis of random variable loads acting on wheels for special off-highway applications from experimental data
Fatigue analysis of random variable loads acting on wheels for special off-highway applications from experimental data
L. Solazzi, A. Mazzoni, N. Danzi, M. Cima
10.48447/VAL5-2024-022
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
random fatigue,damage counting,wheel,stress acquisition 
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Fatigue analysis of random variable loads acting on wheels for special off-highway applications from experimental data
L. Solazzi, A. Mazzoni, N. Danzi, M. Cima
10.48447/VAL5-2024-022
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
random fatigue,damage counting,wheel,stress acquisition
Preis 25,00 €
Nur online erhältlich
Modal driven load tailoring for efficient vibration fatigue assessment on non-stationary processes: A versatile approach exploiting the Fatigue Damage Spectrum
Autor(en): G. Curti, T. Dengler, M. Palmieri, A. Trapp, P. Wolfsteiner, F. Cianetti, K. Schneider
10.48447/VAL5-2024-045
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
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Modal driven load tailoring for efficient vibration fatigue assessment on non-stationary processes: A versatile approach exploiting the Fatigue Damage Spectrum
Modal driven load tailoring for efficient vibration fatigue assessment on non-stationary processes: A versatile approach exploiting the Fatigue Damage Spectrum
G. Curti, T. Dengler, M. Palmieri, A. Trapp, P. Wolfsteiner, F. Cianetti, K. Schneider
10.48447/VAL5-2024-045
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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Modal driven load tailoring for efficient vibration fatigue assessment on non-stationary processes: A versatile approach exploiting the Fatigue Damage Spectrum
G. Curti, T. Dengler, M. Palmieri, A. Trapp, P. Wolfsteiner, F. Cianetti, K. Schneider
10.48447/VAL5-2024-045
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
random vibration loading,non stationary loading,mission syntesis,fatigue damage spectrum,modal decomposition
Preis 25,00 €
Nur online erhältlich
Loading spectra of the trailer chassis
Autor(en): E. Schäfer, V. Chmelko, M. Kučerková
10.48447/VAL5-2024-029
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
multiaxial loading,trailer axle,loading spectra 
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Loading spectra of the trailer chassis
Loading spectra of the trailer chassis
E. Schäfer, V. Chmelko, M. Kučerková
10.48447/VAL5-2024-029
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
multiaxial loading,trailer axle,loading spectra 
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Loading spectra of the trailer chassis
E. Schäfer, V. Chmelko, M. Kučerková
10.48447/VAL5-2024-029
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
multiaxial loading,trailer axle,loading spectra
Preis 25,00 €
Nur online erhältlich
Non-stationary vibration loading - Assessing its effects on structural dynamics and vibration fatigue
Autor(en): A. Trapp, P. Wolfsteiner
10.48447/VAL5-2024-053
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
structural dynamics,non-stationarity matrix,non-stationary vibration loading,random vibration fatigue 
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1
Non-stationary vibration loading - Assessing its effects on structural dynamics and vibration fatigue
Non-stationary vibration loading - Assessing its effects on structural dynamics and vibration fatigue
A. Trapp, P. Wolfsteiner
10.48447/VAL5-2024-053
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Non-stationary vibration loading - Assessing its effects on structural dynamics and vibration fatigue
A. Trapp, P. Wolfsteiner
10.48447/VAL5-2024-053
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
structural dynamics,non-stationarity matrix,non-stationary vibration loading,random vibration fatigue
Preis 25,00 €
Nur online erhältlich
Application of Incremental Step Tests for Screening and Deriving Cyclic Properties of Metal Structures Using the Example of Additively Manufactured AlSi10Mg
Autor(en): B. Möller, M. Scurria, T. Korschinsky
10.48447/VAL5-2024-030
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
additive manufacturing,cyclic material behavior,incremental step test,Fatigue Life Curve,strain-life curve 
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Application of Incremental Step Tests for Screening and Deriving Cyclic Properties of Metal Structures Using the Example of Additively Manufactured AlSi10Mg
Application of Incremental Step Tests for Screening and Deriving Cyclic Properties of Metal Structures Using the Example of Additively Manufactured AlSi10Mg
B. Möller, M. Scurria, T. Korschinsky
10.48447/VAL5-2024-030
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
additive manufacturing,cyclic material behavior,incremental step test,Fatigue Life Curve,strain-life curve 
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1
Application of Incremental Step Tests for Screening and Deriving Cyclic Properties of Metal Structures Using the Example of Additively Manufactured AlSi10Mg
B. Möller, M. Scurria, T. Korschinsky
10.48447/VAL5-2024-030
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
additive manufacturing,cyclic material behavior,incremental step test,Fatigue Life Curve,strain-life curve
Preis 25,00 €
Nur online erhältlich
Computational fatigue assessment for welded copper joints against vibratory loads
Autor(en): M. Lauf, S. Pruy, S. Kiesner, P. Hantschke, M. Kästner
10.48447/VAL5-2024-040
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Vibration Fatigue,Digital Twin,FEM-Simulation,Welded Copper 
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Computational fatigue assessment for welded copper joints against vibratory loads
Computational fatigue assessment for welded copper joints against vibratory loads
M. Lauf, S. Pruy, S. Kiesner, P. Hantschke, M. Kästner
10.48447/VAL5-2024-040
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Vibration Fatigue,Digital Twin,FEM-Simulation,Welded Copper 
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1
Computational fatigue assessment for welded copper joints against vibratory loads
M. Lauf, S. Pruy, S. Kiesner, P. Hantschke, M. Kästner
10.48447/VAL5-2024-040
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Vibration Fatigue,Digital Twin,FEM-Simulation,Welded Copper
Preis 25,00 €
Nur online erhältlich