Finite element modelling approaches for sheet metal joining: A review of techniques and application

Joining for sheet metal is a widely used process in product manufacturing in diverse industries such as automotive, aerospace, electronics, constructions and others. Finite element has become a vital tool when it comes to simulating the structural integrity and performance of many types of joining that are being used such as mechanical fastener, welding, adhesives and many more. This review paper provides a comprehensive overview of finite element modelling techniques applied to sheet metal joining based on existing studies from other researchers. The paper discusses the methods, advantages and limitations for each modelling approaches and highlights their key applications. This paper also discusses the role of finite element analysis when studying the performance of these models for joints. This will enable researchers to predict failure behaviours and enhance design efficiency. The strengths and limitations of various modelling approaches such as simplified and detailed methods and identified key areas for future research and development were also examined. By summarising the current knowledge and methodologies, this paper aims to contribute to the advancement of joint modelling techniques, which can lead to more accurate and reliable modelling method for joining in sheet metal.