Experimental and Numerical Analysis of Formed Tailored Clinched Sheet Using Conventional Forming Process

Abstract

This paper investigates the formability of tailored clinched and plain AA1100 sheet with a thickness of 1 mm. The tailored clinched and plain sheets were subjected to plastic deformation until fracture using a punch-die arrangement, a conventional metal-forming technique. In addition, a numerical simulation was carried out using LS-DYNA Multiphysics to model the clinching process and conventional forming of the plain sheet. The experimental result was verified against the simulation result to assess the accuracy of the simulation model. From the experimental result, it is clear that the formability of the tailored clinched sheet and the plain sheet is 6.84–23.60 mm, respectively. A strong correlation between the experimental and simulation results of the plain sheet was observed, with a deviation of 2%. This study shows that the tailored clinched sheet metal can be successfully formed using a conventional metal-forming technique without causing stress concentration at the joint. © The Indian Institute of Metals - IIM 2026.