Analysis of joint formation mechanisms for self-piercing riveting (SPR) process with varying joining parameters. (January 2022)

• Record Type: Journal Article
• Authors: Zhao, Huan; Han, Li; Liu, Yunpeng; Liu, Xianping
• Is Part Of: Journal of manufacturing processes. Volume 73(2022)
• Page Start: 668
• Page End: 685
• Publication Date: 2022-01
• Subjects: SPR joint -- Formation mechanisms -- FE model -- Interrupted experimental test -- Sheet thickness -- Rivet length; Production management -- Data processing -- Periodicals; Manufacturing processes -- Periodicals; Procestechnologie; Productietechniek; Production -- Gestion -- Informatique -- Périodiques; Fabrication -- Périodiques; Manufacturing processes; Production management -- Data processing; Periodicals; 670.5
• DOI: 10.1016/j.jmapro.2021.11.038
• Languages: English
• ISSNs: 1526-6125

Abstract

Abstract: By combining experimental SPR tests with a finite element (FE) model, the influences of top sheet thickness ( T t ), bottom sheet thickness ( T b ) and rivet length ( L ) on the joint formation mechanisms were systematically investigated in this study. Single factor experiments were firstly conducted to uncover the three joining parameters' effects on the joining results. Interrupted SPR tests were also performed to confirm the prediction accuracy of the FE model on the joint formation process. Then, the joint formation mechanisms were analyzed by numerically inspecting the events during the riveting process, including the sheet deformation behaviors, rivet shank flare behavior and formation of quality indicators. The results revealed that the joining parameters affected the interlock formation by directly altering the positions of two interlock boundaries. The rivet shank flare behavior was apparently affected by the T t and T b, but less influenced by the L. The formation of remaining bottom sheet thickness at the joint center ( T c ) was significantly affected by the T t and T b . Rapid reduction of the T c occurred before the top sheet was penetrated and after the rivet cavity was fully filled. Meanwhile, it is highlighted that the FE model is an excellent tool to analyze SPR joint formation. Graphical abstract: Unlabelled Image Highlights: The formation mechanisms of SPR joints were analyzed experimentally and numerically. The T t, T b and L imposed different effects on the interlock formation. The rivet shank flare behavior was apparently affected by the T t and T b, but not by the L . The formation of T c was significantly affected by the T t and T b, but not by the L . The FE model is an excellent tool to analyze the SPR joint formation.