Working Group B | Form-closed joint & Force-closed joint


Scaling of roller clinching considering process robustness

Prof. Dr. Wolfram Volk, Lehrstuhl für Umformtechnik und Gießereiwesen
Dr.-Ing. Roland Golle, Lehrstuhl für Umformtechnik und Gießereiwesen


Compared to processes using stroke movements, manufacturing processes with rotational tool movements offer many benefits, especially for processing semi-finished coil products. Roller clinching uses these positive characteristics and enables a continuous joining process while maintaining high speed (Figure 1).

Figure 1: Schematic description of roller clinching
Figure 1: Schematic description of roller clinching

In the first two funding periods of the SPP 1640 initially the basic feasibility of roller clinching was investigated. Then the range of applications for roller clinching was extended. Using a prehole offered the ability to join materials, which are difficult to form, with well formable materials. The studies were carried out within very narrow parameter limits, which were specified through the existing roller clinching setup. To gain a complete understanding of the process and to extend the range of use, the concept will be transferred to different dimensions now (Figure 2). The process limits as well as the process robustness, which is directly linked to the scaling of the process due to the special kinematics, are part of the investigation. Based on the results of previous projects, the focus will now be placed in particular on the scalability and robustness of the joining process. The objective of the project is to expand the process window regarding different application areas.

Figure 2: Parameter for the investigation of the scalability of the process
Figure 2: Parameter for the investigation of the scalability of the process

The main objectives of the project:

  • Kinematics analysis of the roller clinching in an extended parameter area
  • Investigation of effects of the scaling of roller clinching processes regarding the sheet thickness, the roller radius and the process velocity
  • Identification of robust and technical realizable process parameter
  • Setup of a test bed to determine the effects of scaling on the clinch point properties as well as the mechanical properties of the joint


  Experimental Investigation of the Scalability of Roller-Clinching Processes with regard to Joint Strength and Failure Mode Vitzthum, S.; Hiller, M.; Volk, W.
In: Journal of Material Science and Engineering Technology, 2019
  Numerical Investigation on the Robustness of the Roller Clinching Process Vitzthum, S.; Sturm, P.; Hiller, M.; Volk, W.
In: International Journal of Material Forming (ESAFORM), 2019
  Tool setup to investigate scalability of roller clinching processes Vitzthum, S.; Hiller, M.; Dinh, D. T.; Volk, W.
In: Procedia Manufacturing, Vol. 15, 1338-1345, 2018
  Numerical Analysis of the Scalability of Roller Clinching Processes Hiller, M.; Vitzthum, S.; Hacker, M.; Benkert; T.; Volk, W.
In: Key Engineering Materials, 767, 377-385, 2018
  Influence of tool elasticity on process forces and joint properties during clinching with rotational tool movement Hiller, M.; Benkert, T.; Vitzthum, S.; Volk, W.
In: Journal of Physics: Conference Series, 896, 012116, 2017
  Joining by Plastic Deformation: Overview of the DFG Priority Program 1640 Hiller, M.; Volk, W.
In: Advanced Multimaterial Structures in the Automotive Industry, Bilbao, 2016
  Joining Aluminium Alloy and Mild Steel Sheets by Roller Clinching Hiller, M.; Volk, W.
In: Applied Mechanics and Materials 794, 2015, 295–303
  Einfluss von Reibung auf die Verbindungsausbildung beim Rotationsclinchen Weiß, M.; Volk, W.
In: 18. Workshop Simulation in der Umformtechnik & 3. Industriekolloquium des SFB/TR73, Shaker Verlag, 2015, 211–213
  Influence of Kinematics during Roller Clinching on Joint Properties Weiß, M.; Volk, W.
In: Journal of Manufacturing Science and Engineering 137(5), 2015, 051016
  Simulation assisted analysis of material flow in roller clinched joints. Rill, D.; Weiß, M.; Hoffmann, H.; Volk, W.
In: Advanced Materials Research 966–967, 2014, 628–640

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