以热熔胶膜作为粘接剂，开展压印/粘接复合连接工艺试验研究，基于Box-Behnken设计（BBD）方法，建立因素（冲压力、胶膜厚度、板材硬度）与响应值（能量吸收值、失效载荷）之间的多元回归方程，辨析因素与响应值之间的内在联系，结合接头机械内锁结构的有限元模型，分析接头断裂失效模式。结果表明：多元回归模型具备较高的显著性且拟合程度高，能量吸收值、失效载荷的试验值与预测值的最大误差分别为7.9%、11.42%，验证了模型的可靠性。冲压力与能量吸收值和失效载荷均呈正相关性，胶膜厚度对能量吸收值和失效载荷的影响均呈先减小后增大的趋势；胶膜的加入对接头的力学性能有较明显的提升；当接头受拉时，接头发生以拉脱失效和混合失效（拉脱和颈部断裂同时发生）为主的失效模式，有限元分析与试验吻合较好。

Hot melt adhesive film was used as adhesive to carry out the experimental research on the composite bonding process of clinch-bonding. Based on Box-Behnken Design （BBD） method， the multiple regression equation between factors （punch pressure， film thickness， sheet hardness） and response values （energy absorption value， failure load） was established， and the internal relationship between factors and response values was analyzed. Combined with the finite element model of mechanical internal locking structure of joint， the fracture failure mode of joint was investigated. The results show that the multiple regression model has high significance and high fitting degree， and the maximum error of energy absorption value and failure load between the experimental value and the predicted value is 7.9% and 11.42%， which verifies the reliability of the model. The punch pressure is positively correlated with energy absorption value and failure load， and the influence of film thickness on energy absorption value and failure load decreases first and then increases. The mechanical properties of the joint are obviously improved by adding film. When the joint is under tension， the failure mode is mainly pull-off failure and mixed failure （pull-off and neck fracture occur simultaneously）， and the finite element analysis is in good agreement with the test.