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Analysis of Sheet Metal Joining with Self-Piercing Riveting
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on April 14, 2020 by SAE International in United States
Self-piercing riveting (SPR) has been in production in automotive industry since early 1990s. A substantial amount of experimental work was traditionally required in order to find an appropriate combination of rivet and anvil design to satisfy the required joint parameters. Presented study is describing the methodology of numerical simulation of SPR process and its experimental validation for Aluminum alloys and steels. Among material properties, the required information for numerical simulation includes stress-strain curves validated for the range of strains taking place in SPR process (up to 2.0 of true strain for sheets and up to 0.4 of true strain for the rivet) and parameters of fracture model for all involved materials: all sheets in the stack and the rivet material. Experimental data on stress-strain curves for extended range of strains was obtained based upon multistep rolling tensile testing procedure for the sheet metals. Parameters of the fracture model for sheets were defined by custom hole expansion test, and the parameter of the fracture model for the rivet was defined via expanding the tubular portion of the rivet in heat treated condition. Special attention is paid to identifying coefficients of friction between the sheet metals being joined as well as between the bottom sheet and the riveting anvil.