Process Simulation Applications

in Mechanical Joining
by:
James B. Miller, Prinsipal Research Scientist
and John Walters, Vice President
Scientific Forming Technologies Corporation
5038 Reed Road
Columbus, OH 43220-2514 USA
www.deform.com

The benefits of simulating fasteners and

mechanical joining are numerous.

Cold forming product development cycles have become

more sophisticated over the last few decades. CAD/CAM,
solid modeling, process simulation and a wide range of testing and monitoring have led to reduced development cycles
for leading manufacturers.
The use of process simulation in progression development
and tool failure analysis is well documented. The tools that
were developed for metal forming are also being applied to
mechanical joining applications.
Mechanical joining represents a wide range of fastening
methods. These methods include conventional, clinching,
self-piercing, self-threading and blind fastening. Rivets,
screws, nuts and inserts are some typical products utilized
by manufacturers to join by forming. Alternative forming
processes have even involved joints formed using the joined
components themselves. The extensive array of mechanical
joining techniques is the result of OEMs constantly looking for
a better mousetrap to reduce assembly labor, time and cost.
The simulation of two-dimensional (axisymmetric/round)
mechanical joining processes was initially reported in the
1990s. The three-dimensional analysis of more complex
joining systems has become practical in recent years. This is
the result of improvements in software codes and hardware
speeds. Clever and creative engineers have continued to push
the simulation capability as one means of gaining a competitive edge. Each success story leads to more wide-spread application of modeling.
The primary objective of computer modeling for most
companies is a reduction in the development cycle. Secondary goals include process optimizations, testing lower-cost
alternatives, reducing development costs, freeing development time for production and troubleshooting problems. The
ability to predict forming defects, tool failures, joint strengths
and more prior to spending any money on shop trials is extremely attractive. The following applications represent a
range of mechanical joining simulation examples using the
DEFORM system.

Drawform Studs
When faced with long development times for a proprietary
fastening system, the Multifastener division of FabriSteel
deployed process simulation. The development cycle included
the forming progression, installation tooling and process
and testing of the installed joint. Changes to the forming
process influenced both the installation and test results, thus
independent parallel development of forming and installation
was impractical.
An application first published in the late 1990s was a drawform stud. The drawform stud is a cold formed part that is clinch
joined to sheet metal. It is used in the automotive industry to
mount drive train and body components to the chassis.
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Fastener Technology International/October 2007

The cold forming process for this part involved multiple

sequential processes. This forming process included draw,
extrusion and heading operations. These operations were
analyzed in order to predict the final deformed part shape. The
results also provided an estimate of the part fill, forming loads
and die stresses that would be encountered. A single workpiece was analyzed through the entire production process.
Thus, simulation captured the cumulative work hardening
effect on the part.
The plastic strain (cold work) distribution is critical to the
accurate modeling of any mechanical joining process. This
influences the deformation during installation and in-service
performance. As the model was calibrated, excellent correlation of forming and installation was obtained. In fact, the pull
test was predicted within 10%.
The resulting model allowed the engineers to virtually test a
forming, installation and pull sequence in a matter of hours or
days. The time to market for new products or derivatives was
reduced significantly. See the drawform stud in Figure 1.

Fig. 1 The drawform stud is shown after installation (top

left) and pull test (top right). Strain contours (red is higher)
on the stud include work hardening as a result of the prior
forming operations. A front (bottom-left) and rear (bottom
right) view of the installed fastener is shown.

Pierce Nuts
The pierce nut provides a mechanically joined nut analogous to the drawform stud. The pierce nut is not round (axisymmetric), thus a three-dimensional simulation is required
to model the forming and installation. Until the last few years,
this was impractical. Recent developments in software and
computer hardware have changed this.
The installation of the pierce nut was plastically simulated
using deformable nut and sheet geometries. The installation
was set up just as it would be in service. A top punch and bottom die supported and compressed the nut and sheet together.

Mechanical Joining Simulation

The setup was similar to many forming simulation setups,
yet it contained the multiple deforming bodies. Appropriate
material properties were specified for each deformable object.
Since the sheet was much softer than the nut, the sheet had
the majority of the deformation. The installation process was
evaluated to determine that an appropriate clinch joint had
been formed. See the pierce nut installation in Figure 2.

Fig. 2 Pierce nut installation on sheet metal using punch

and die. A strip of nuts (center) prior to installation and a
typical installation (right) are shown.

Breakaway Locks
Hercules Industries, a manufacturer of brass padlocks,
used simulation to develop an aluminum breakaway padlock. These locks are used for cable boxes and other low
security requirements. The locks are installed by tightening
a breakaway bolt until the head shears off. They are subsequently opened by bolt cutters and discarded. A 500 lb pull
strength is required by most customers to keep the honest
people from easily opening the locks.
Initial trial-and-error developments were slow. Multiple
changes from trial-to-trial led to confusion about the influence of each change. The process was modeled to include
two steps. First, a bolt was installed until the head sheared
off. This resulted in the end of the bolt plastically deforming
the shackle. The pull strength was determined by pulling the
shackle away from the body with a rigid bar.
During this development, the grade of aluminum, heat treatment, shackle diameter and lock body geometry were primary
variables. Common aluminum alloys were analyzed including
heat treatment variations of 6061 and 6062. A very aggressive
cost goal was inflexible with a limit of three components. Simulation results matched prototype tests very accurately.
This manufacturer got to market faster and with fewer
trials than using trial-and-error. Experienced designers could
process a new design in a day, whereas shop trials could take
a week. When in doubt, extra computer simulations could
be used to understand the influence of each change. See the
breakaway lock simulation summary in Figure 3.

Fig. 3 A simulation summary of the breakaway lock shows

the deformed parts and pull load graphs. Design variations presented left to right represent locks of increasing pull strength
capability. An early production lock is seen on the right.

Clinching Fasteners
Companies are finding increasing use for clinching fasteners in automotive applications. These fasteners quickly form a

Linear elastic stress analysis is very common for commercial programs such as ANSYS, COSMOS and ALGOR. The analysis of
multiple deforming bodies during small deflection is also possible
for some general-purpose FEM codes. Accurate simulation of
large (plastic) deformation has been the strength of metal forming
process simulation programs such as DEFORM. The simulation of
large deformation processes such as cold forming requires a robust
automatic remeshing and contact algorithm. Large deformation
mechanical joining is an acid test for any simulation program.
Simplified assumptions and programs are no better than entering
the family car in a NASCAR race.
Successful mechanical joining simulation requires a very efficient
and robust meshing algorithm. The mesh size must be optimized
for both initial mesh generation and in-process remeshing. Mesh
size should be automatically adapted in specific areas based on
solution behavior such as curvature, strain and strain rate. The
fully-automatic mesh generator should retain a fine mesh in contact
regions throughout the simulation to achieve an accurate result.
Modeling of multiple deforming bodies is not feasible without a
sophisticated arbitrary contact algorithm. Discrete models with
independent, arbitrary contact between object pairs are an absolute requirement. The contact calculation must be automatically
updated for each object at each time step. Predetermined contact
(required by some general purpose systems) is inadequate for
large deformation mechanical joining processes.
Finally, a successful mechanical joining simulation requires the
plastic strain (cold work) distribution in each component. The
local strength in cold forming operations is directly related to the
deformation history. A different forming operation results in variation in pull strength, shear strength and other mechanical metrics.
It is impossible to accurately model a mechanical joining process
without including the prior forming operations.

strong joint between multiple pieces of sheet metal. A clinching

fastener is formed into the sheet metal components and remains
within the completed joint. Installation tools are simple since the
fastener does the forming. The resulting joint is a permanent,
flush joint intended to replace welds or rivets.
The SpotFast fastener, developed by PennEngineering,
is an example of a clinching fastener. To save both time and
money during the design cycle, engineers used process simulation. Engineers simulated different clinch profiles, materials and hole sizes. This allowed them to try several designs
without cutting a single piece of steel.
The two sheets being joined were mounted one directly on
top of the other. Simulations took deformation of each sheet
and interaction between the two into account. Multi-body,
plastic deformation predictions were calculated using the
simulation software. This provided engineers with the ability to instantly evaluate joint cross-sections on the computer.
The alternative was physical installation trials and processing
of cross-section cut samples. See the SpotFast fastener application in Figure 4.
Fig. 4 A
SpotFast
fastener is
installed into
multiple
deformable
sheets of metal.
Cross-section
photo provides
one example of
an installed part.
October 2007/Fastener Technology International

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Process Simulation Applications in Mechanical Joining...Continued

Monobolt Breakstem Fasteners
Teams at Avdel UK Limited have found extensive use for
simulation in their product development cycle. Innovative
fastening solutions are developed at Avdel for the automotive
and commercial markets. Engineers have integrated simulation into prototype and production design routines. Correlation
studies on fastener forming, installation and testing show that
simulation results can compare well to real life results.
A compression simulation study was performed on the
Avdel Monobolt using a number of plastically deformable
objects. From these simulation results, stresses and strains in
all of the deformable objects were available. Tool loads were
also determined on the installation equipment. This allows
optimization of the installation tools, based on deformation
and loads. See the Monobolt simulation in Figure 5.
Fig. 5 Monobolt
simulation depicts
the deforming shape
of each object during
the installation. The
cross-section display
allows a view inside
of this 3D simulation
as multiple objects
are deforming
simultaneously.

Ongoing Fastening Methods Development

New mechanical joining products and methods are introduced every
year. Target markets for these products include the automotive,
aerospace, medical and commercial applications. New fasteners
are being designed for improved performance over existing methods. They have also been developed to replace more costly joining
methods such as welding. Leading manufacturers are targeting
custom applications as an alternative to the low margin commodity
fastener markets. Products developed using simulation software
can provide a time-to-market, cost and quality advantage over
traditional trial-and-error methods.
Carl Hersant, Engineering Manager of Avdel UK
Limited, has proven the benefits of simulation
within his organization. Hersant found that analysis first saves time and money when developing
new products. Avdel has shown that simulation
gives the company another tool to learn more about
its processes. Simulation utilizes the expertise of
users, thus providing enhanced information about
a particular process. As Hersant puts it, Analysis
Carl
is backed up by years of experience and technical
Hersant
knowledge.
The role of simulation in the development of new joining methods
and products is important. Simulations allow new ideas to be evaluated on the computer with little risk. The frequency of prototyping
runs that interrupt production can be minimized. Virtual testing can
be accomplished on the computer to predict product performance.
This all keeps the factory producing and reduces prototyping time,
labor crunches and financial costs.

Blind Rivet Nuts

Conclusion

Complex fasteners take many shapes and sizes. Blind rivet

nuts represent a complex fastener that can be challenging to
develop. These fasteners are inserted into holes and deformed
to clamp around the hole. The installed fasteners provide
strong thread interfaces in thin or weak material. This allows
bolts or screws to later be installed into the nut.
The blind rivet nut case pushes the boundaries of mechanical joining simulation. Evolving contact occurs as the threaded
installation tool interface rotates and moves axially. Fine
threads require areas of fine mesh resolution. Localized remeshing and self-contact conditions are essential to modeling the
body-to-body contact in the folded bulb area of the fastener.
Rigid installation tools can be controlled by speed, load, rotation, torque or combination of these. With the blind rivet, linear
deformation was induced in the part via rotation of a screw
thread. Without proper tools, prediction of the grossly deformed
final shape is nearly impossible. Modeling this application type
can also determine grip length ranges for the fastener. See the
example of an installed blind rivet nut in Figure 6.

The benefits of simulating fasteners and mechanical joining

are many. The development of new joining methods or more
advanced products is possible. New fastening techniques
or tools can be quickly designed in an iterative procedure.
Process optimization can take place before tools hit the shop
floor. Finally, virtual performance testing can be analyzed to
determine product specifications.
Mechanical joining development represents a field of constant change. Significant investments may need to be made
prior to production runs. Accelerating the development cycle
is critical in reducing time-to-market. Typical trial-and-error
procedures are often experience-based and linked to individuals. Simulation can influence designs and processes prior to
consuming large quantities of time and money.
Scientific Forming Technologies Corporation has a demonstration CD that contains animated examples of mechanical
joining simulations. Please contact the company if you would
like to request a CD and for more information on DEFORM.

Fig. 6 An example of an installed blind rivet nut is shown

above. Five stages of installation are shown. The installation
is driven by thread rotation. Self-contact is included in the
contact calculation at later stages.
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Fastener Technology International/October 2007

FTI

Author Profile:
Scientific Forming Technologies Corporation (SFTC)
develops and supports the DEFORM System. DEFORM
is an engineering software that enables designers to analyze metal forming, heat treatment, machining and mechanical joining processes on the computer. Process simulation using DEFORM has been instrumental in cost,
quality and delivery improvements at leading companies
for nearly two decades. SFTC is also available for consulting, training, contract simulation, project management and software development on a project basis.