Characterisation of residual stress distribution in clinching joints of carbon steel by diffraction methods

Sheet joints of carbon steel fabricated by two different clinching methods, namely TOX and Eckold, have been investigated. The holding force of the joints was determined by shear tension tests and the deformation microstructure was characterised using optical microscopy. The surface residual stress and mean residual stress distributions as a function of increasing distance from the outer diameter of the interlock button were. mapped by X-ray and neutron diffractometry, respectively. The Eckold joints showed more severe joint distortion in the form of global sheet bending, but nevertheless possessed higher shear tension strength than the TOX joints. Characteristic residual stress distributions depending on the clinching method were found in both the TOX and Eckold joints. The observed residual stress distributions have been attributed to the different die construction employed by the two methods, which permitted different degrees of plastic deformation during clinching.