Influence of the Friction Coefficient in Self-Pierce Riveting Simulations: A Statistical Analysis

In this work, optimal modeling parameters for self-pierce riveting (SPR) were determined using a factorial design of experiments (DOE). In particular, we show statistically how each of the calibrating parameters used in modeling the SPR process through nonlinear finite element modeling can drastically change the geometry of the joint. The results of this study indicate that the degree of interlock, which is a key feature of a sound joint, is largely influenced by the friction between the die and bottom sheet as well as the friction between the rivet and top sheet. Furthermore, this numerical study also helped elucidate the role of friction in SPR and sheds light on how coatings with diverse friction coefficients can affect material deformation and ultimately structural integrity of the joint.