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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.

Reference
VAL5-2024-046

Title
Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions
Author(s)
B. Spak, M. Schlicht, P. Froitzheim, W. Flügge, M. Kästner
DOI
10.48447/VAL5-2024-046
Event
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
Year of publication
2024
Publication type
conference paper (PDF)
Language
English
Keywords
Clinching,mechanical joining,Local Strain Approach,fatigue,variable amplitude loading

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A fatigue damage assessment approach in vibration fatigue exploiting the static approach
A fatigue damage assessment approach in vibration fatigue exploiting the static approach
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A Comparative Analysis: Time vs. Frequency Domain Definitions of the Fatemi-Socie Criterion
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A. Niesłony, M. Böhm, M. Sgamma, A. Chiocca, F. Bucchi, F. Frendo
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VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
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English
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A Comparative Analysis: Time vs. Frequency Domain Definitions of the Fatemi-Socie Criterion
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10.48447/VAL5-2024-037
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2024
conference paper (PDF)
English
Fatemi-Socie criterion,frequency domain,vibration fatigue,multiaxial fatigue
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A critical plane criterion for non-stationary random vibration loading applicable in a statistical fatigue assessment
Author(s): A. Trapp, K. Schneider, K. Rother, P. Wolfsteiner
10.48447/VAL5-2024-048
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conference paper (PDF)
English
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A critical plane criterion for non-stationary random vibration loading applicable in a statistical fatigue assessment
A. Trapp, K. Schneider, K. Rother, P. Wolfsteiner
10.48447/VAL5-2024-048
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publication type: conference paper (PDF)
English
critical plane criterion,non-stationary loading,non-stationarity matrix,multiaxial fatigue,random vibration fatigue 
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A critical plane criterion for non-stationary random vibration loading applicable in a statistical fatigue assessment
A. Trapp, K. Schneider, K. Rother, P. Wolfsteiner
10.48447/VAL5-2024-048
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
critical plane criterion,non-stationary loading,non-stationarity matrix,multiaxial fatigue,random vibration fatigue
Price €25.00
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conference paper (PDF)
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VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
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English
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Probabilistic fatigue crack propagation assessment of hydrogen pipelines
P.M. Kyaw, M. Braun
10.48447/VAL5-2024-057
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
Probabilistic analysis,fatigue,crack propagation,hydrogen pipeline
Price €25.00
Online only
Non-stationary vibration loading - Assessing its effects on structural dynamics and vibration fatigue
Author(s): A. Trapp, P. Wolfsteiner
10.48447/VAL5-2024-053
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
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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
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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
conference paper (PDF)
English
structural dynamics,non-stationarity matrix,non-stationary vibration loading,random vibration fatigue
Price €25.00
Online only
Modal driven load tailoring for efficient vibration fatigue assessment on non-stationary processes: A versatile approach exploiting the Fatigue Damage Spectrum
Author(s): 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
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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
Publication type: conference paper (PDF)
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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
conference paper (PDF)
English
random vibration loading,non stationary loading,mission syntesis,fatigue damage spectrum,modal decomposition
Price €25.00
Online only
Influence of variable amplitude loading on copper-alloyed components
Author(s): M. Hupka, M. Wächter, A. Esderts
10.48447/VAL5-2024-042
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
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Influence of variable amplitude loading on copper-alloyed components
Influence of variable amplitude loading on copper-alloyed components
M. Hupka, M. Wächter, A. Esderts
10.48447/VAL5-2024-042
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
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1
Influence of variable amplitude loading on copper-alloyed components
M. Hupka, M. Wächter, A. Esderts
10.48447/VAL5-2024-042
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
Copper Alloys,Analytical Fatigue Assessment,Component-related Influences
Price €25.00
Online only
Application of Incremental Step Tests for Screening and Deriving Cyclic Properties of Metal Structures Using the Example of Additively Manufactured AlSi10Mg
Author(s): 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
conference paper (PDF)
English
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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
Publication type: conference paper (PDF)
English
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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
conference paper (PDF)
English
additive manufacturing,cyclic material behavior,incremental step test,Fatigue Life Curve,strain-life curve
Price €25.00
Online only
An efficient algorithm for critical plane search in random multiaxial fatigue based on Maximum Variance Method, 3D matrices and Hadamard’s element-wise product.
Author(s): D. Benasciutti
10.48447/VAL5-2024-006
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
random loading,critical plane,maximum variance 
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An efficient algorithm for critical plane search in random multiaxial fatigue based on Maximum Variance Method, 3D matrices and Hadamard’s element-wise product.
An efficient algorithm for critical plane search in random multiaxial fatigue based on Maximum Variance Method, 3D matrices and Hadamard’s element-wise product.
D. Benasciutti
10.48447/VAL5-2024-006
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publication type: conference paper (PDF)
English
random loading,critical plane,maximum variance 
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1
An efficient algorithm for critical plane search in random multiaxial fatigue based on Maximum Variance Method, 3D matrices and Hadamard’s element-wise product.
D. Benasciutti
10.48447/VAL5-2024-006
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
random loading,critical plane,maximum variance
Price €25.00
Online only
Fatigue strength assessment of tube-to-flange welded steel joints with reinforcement ribs under variable amplitude loadings according to the Peak Stress Method
Author(s): 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
conference paper (PDF)
English
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
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
Publication type: conference paper (PDF)
English
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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
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
conference paper (PDF)
English
Steel welded joints,Variable Amplitude loads,Fatigue testing,Peak Stress Method,Automated fatigue strength assessment
Price €25.00
Online only
Statistical method and associated non-linear cumulative model for fatigue nuclear applications
Author(s): 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
conference paper (PDF)
English
Nuclear industry,Probabilistic models and methods,Amplitude-dependant models,Nonlinear cumulative damage 
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1
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
Publication type: conference paper (PDF)
English
Nuclear industry,Probabilistic models and methods,Amplitude-dependant models,Nonlinear cumulative damage 
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1
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
conference paper (PDF)
English
Nuclear industry,Probabilistic models and methods,Amplitude-dependant models,Nonlinear cumulative damage
Price €25.00
Online only
Modification of the Findley Damage Parameter for Fatigue Assessment under multi-axial proportional and non-proportional variable Amplitude Loading
Author(s): C. Fällgren, M. Vormwald
10.48447/VAL5-2024-021
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
fatigue,Findley parameter,non-proportional loading,multi-axial loading,critical plane method 
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1
Modification of the Findley Damage Parameter for Fatigue Assessment under multi-axial proportional and non-proportional variable Amplitude Loading
Modification of the Findley Damage Parameter for Fatigue Assessment under multi-axial proportional and non-proportional variable Amplitude Loading
C. Fällgren, M. Vormwald
10.48447/VAL5-2024-021
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publication type: conference paper (PDF)
English
fatigue,Findley parameter,non-proportional loading,multi-axial loading,critical plane method 
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1
Modification of the Findley Damage Parameter for Fatigue Assessment under multi-axial proportional and non-proportional variable Amplitude Loading
C. Fällgren, M. Vormwald
10.48447/VAL5-2024-021
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
fatigue,Findley parameter,non-proportional loading,multi-axial loading,critical plane method
Price €25.00
Online only
Comparative Study of Crack Growth Retardation Models for an Integral Stiffened Panel Subjected to Overload.
Author(s): J. D. Mattos, M. A. Arbelo
10.48447/VAL5-2024-039
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
Overload Retardation Effect,Fatigue Crack-Growth,Integral Stiffened Panel,Aviation Integral Panel 
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1
Comparative Study of Crack Growth Retardation Models for an Integral Stiffened Panel Subjected to Overload.
Comparative Study of Crack Growth Retardation Models for an Integral Stiffened Panel Subjected to Overload.
J. D. Mattos, M. A. Arbelo
10.48447/VAL5-2024-039
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publication type: conference paper (PDF)
English
Overload Retardation Effect,Fatigue Crack-Growth,Integral Stiffened Panel,Aviation Integral Panel 
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1
Comparative Study of Crack Growth Retardation Models for an Integral Stiffened Panel Subjected to Overload.
J. D. Mattos, M. A. Arbelo
10.48447/VAL5-2024-039
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
Overload Retardation Effect,Fatigue Crack-Growth,Integral Stiffened Panel,Aviation Integral Panel
Price €25.00
Online only
A demonstrator example for virtual sensing approaches in predictive maintenance applications
Author(s): L. Heindel, P. Hantschke, M. Kästner
10.48447/VAL5-2024-049
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
virtual sensing,predictive maintenance,machine learning 
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1
A demonstrator example for virtual sensing approaches in predictive maintenance applications
A demonstrator example for virtual sensing approaches in predictive maintenance applications
L. Heindel, P. Hantschke, M. Kästner
10.48447/VAL5-2024-049
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
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A demonstrator example for virtual sensing approaches in predictive maintenance applications
L. Heindel, P. Hantschke, M. Kästner
10.48447/VAL5-2024-049
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
conference paper (PDF)
English
virtual sensing,predictive maintenance,machine learning
Price €25.00
Online only
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
Author(s): 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
conference paper (PDF)
English
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum 
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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
Publication type: conference paper (PDF)
English
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
conference paper (PDF)
English
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum
Price €25.00
Online only