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Double-sided self-pierce riveting: analysis of the mechanisms behind the chamfered angle position

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Abstract

Due to the hidden joint structure, good joining strength, and simple die structure, double-sided self-pierce riveting (DSSPR) has been seen as a potential alternative to self-pierce riveting or resistance spot welding. The chamfered angle position, a new design parameter of tubular rivets, has been proved to influence the joining strength significantly. However, the corresponding mechanism is still unclear. In this paper, the DSSPR experiments of Al 5052 aluminum alloy sheets using tubular rivets with five chamfered angle positions were carried out. The finite element analysis was adopted to clarify the influence mechanism of the chamfered angle position on the joining strength. Mechanical properties and energy absorption were investigated through single-lap shear tests and cross-tension joint pull-out tests. The deformation behavior of sheets and rivet during the DSSPR process were investigated systematically using finite element simulation. The results showed that chamfered angle position has a significant effect on the section structure and mechanical performance of the joint. The shear strength of l = 0.25 and the pull-out strength of l = 0 were about 125% and 221% higher than that of l = 0.5, respectively. In addition, the counter force F1 influences the rivet expansion direction, and the forces F2 and F3 mainly affect the rivet bending degree. The finite element simulation can effectively predict the material flow, stress, and strain distribution of the rivet and sheets during the DSSPR process. When l = 0 or 0.25, the sheet material flows to the outside of the rivet, and a vortex-like phenomenon is formed at the chamfered position. The influence mechanism of the chamfered angle position on the DSSPR process is discussed and explained. The results can provide a deep understanding of the DSSPR process and help to accelerate its engineering application.

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Funding

This research is supported by the Scientific Research Program Funded by Education Department of Shaanxi Provincial Government (Program No. 22JP010), the Natural Science Basic Research Program of Shaanxi (Program No.2023-JC-YB-379), the National Natural Science Foundation of China (No.51805309, No.52275329), and The Youth Innovation Team of Shaanxi Universities.

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Authors and Affiliations

  1. College of Mechanical & Electrical Engineering, Shaanxi University of Science and Technology, Xi’an, 710021, China

    Pengyi Wang, Jiageng Jin, Yucong Wang, Changsong Zhang, Gehui Wan & Xueni Zhao

  2. School of Materials Science and Engineering, Henan University of Science and Technology, Luoyang, 471023, China

    Nan Xiang

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  1. Pengyi Wang
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  2. Jiageng Jin
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  3. Yucong Wang
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  4. Changsong Zhang
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  5. Gehui Wan
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  7. Xueni Zhao
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Correspondence to Pengyi Wang.

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Wang, P., Jin, J., Wang, Y. et al. Double-sided self-pierce riveting: analysis of the mechanisms behind the chamfered angle position. Int J Adv Manuf Technol 126, 325–337 (2023). https://doi.org/10.1007/s00170-023-11127-4

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  • DOI: https://doi.org/10.1007/s00170-023-11127-4

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