Skip to main content

Advertisement

SpringerLink
Log in

Investigation and optimization of structural parameters for the forming quality and mechanical properties of CFRP/Al self-piercing riveting

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The effects of structural parameters on the forming quality and mechanical properties of CFRP (carbon fiber reinforced polymer)/Al (aluminum) self-piercing riveting (SPR) were investigated and optimized by combining experiment and numerical simulation. Firstly, the SPR 3D finite element model (FEM) was established, in which a continuous damage model (CDM) based on the strain-determined Hashin failure criterion was established to simulate the intra-layer damage of CFRP, and the inter-layer damage was simulated by using cohesive behavior. Subsequently, the effects of rivet length, die diameter, die depth, sheet thickness and width, rivet end distance, and CFRP layup sequence on the SPR cross-sectional dimensions (interlock, bottom remaining thickness) and shear results (peak shear load, energy absorption) were systematically investigated based on the established FEM. Finally, a multi-objective optimization of the structural parameter combinations was performed using Grey relational analysis (GRA) combined with entropy weight method. The results showed that the interlock increased with the increase of rivet length and die diameter, and decreased with the increase of die depth and sheet thickness. The peak shear load increased with the increase of sheet width and rivet end distance. The peak shear load of the joint with [0°/90°]3 s was the largest and the energy absorption of the joint with complex layups was the largest. Normally, the peak shear load and energy absorption were proportional to the interlock. The final optimized combination of joint parameters achieved significant improvement in each indicator compared with the original FEM.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

Data availability

The data used to support the findings of this study are included within the article.

References

  1. Wang J, Zhang G, Zheng X, Li J, Li X, Zhu W, Yanagimoto J (2021) A self-piercing riveting method for joining of continuous carbon fiber reinforced composite and aluminum alloy sheets. Compos Struct 259:113219

  2. Liu Y, Zhuang W (2019) Self-piercing riveted-bonded hybrid joining of carbon fibre reinforced polymers and aluminium alloy sheets. Thin Wall Struct 144:106340

  3. Galinska A, Galinski C (2020) Mechanical joining of fibre reinforced polymer composites to metals-a review. Part II: riveting, clinching, non-adhesive form-locked joints, pin and loop joining. Polymers 12(8):1681

  4. Zhao H, Han L, Liu Y, Liu X (2021) Modelling and interaction analysis of the self-pierce riveting process using regression analysis and FEA. Int J Adv Manuf Technol 113(1–2):159–176

    Article  Google Scholar 

  5. Xie Z, Zhang A, Yan W, Zhang Y, Mu T, Yu C (2021) Study on shear performance and calculation method for self-pierce riveted joints in galvanized steel sheet. Thin Wall Struct 161:107490

  6. Du Z, Duan L, Jing L, Cheng A, He Z (2021) Numerical simulation and parametric study on self-piercing riveting process of aluminium–steel hybrid sheets. Thin Wall Struct 164:107872

  7. Zhang X, He X, Xing B, Wei W, Lu J (2020) Quasi-static and fatigue characteristics of self-piercing riveted joints in dissimilar aluminium-lithium alloy and titanium sheets. J Mater Res Technol 9(3):5699–5711

    Article  Google Scholar 

  8. Zhang X, He X, Xing B, Wei W, Lu J (2020) Pre-holed self-piercing riveting of carbon fibre reinforced polymer laminates and commercially pure titanium sheets. J Mater Process Tech 279:116550

  9. Kam D, Jeong T, Kim J (2020) A quality study of a self-piercing riveted joint between vibration-damping aluminum alloy and dissimilar materials. Appl Sci 10(17):5947

  10. Liu Y, Li H, Zhao H, Liu X (2019) Effects of the die parameters on the self-piercing riveting process. Int J Adv Manuf Tech 105:3353–3368

    Article  Google Scholar 

  11. Jiang H, Gao S, Li G, Cui J (2019) Structural design of half hollow rivet for electromagnetic self-piercing riveting process of dissimilar materials. Mater Design 183:108141

  12. Ma Y, Lou M, Li Y, Lin Z (2018) Effect of rivet and die on self-piercing rivetability of AA6061-T6 and mild steel CR4 of different gauges. J Mater Process Tech 251:282–294

    Article  Google Scholar 

  13. Xu Y (2013) Effects of factors on physical attributes of self-piercing riveted joints. Sci Technol Weld Joi 11(6):666–671

    Article  Google Scholar 

  14. Porcaro R, Hanssen A, Langseth M, Aalberg A (2006) Self-piercing riveting process: an experimental and numerical investigation. J Mater Process Tech 171(1):10–20

    Article  Google Scholar 

  15. Hoang N, Langseth M, Porcaro R, Hanssen A (2011) The effect of the riveting process and aging on the mechanical behaviour of an aluminium self-piercing riveted connection. Eur J Mech a-Solid 30(5):619–630

    Article  MATH  Google Scholar 

  16. Moraes J, Jordon J, Su X, Barkey M, Jiang C, Ilieva E (2019) Effect of process deformation history on mechanical performance of AM60B to AA6082 self-pierce riveted joints. Eng Fract Mech 209:92–104

    Article  Google Scholar 

  17. Zhao H, Han L, Liu Y, Liu X (2022) Analysis of joint formation mechanisms for self-piercing riveting (SPR) process with varying joining parameters. J Manuf Process 73:668–685

    Article  Google Scholar 

  18. Drossel W, Mauermann R, Grutzner R, Matthess D (2013) Numerical and experimental analysis of self piercing riveting process with carbon fiber-reinforced plastic and aluminium sheets. Key Eng Mater 554–557:1045–1054

    Article  Google Scholar 

  19. Hirsch F, Müller S, Machens M, Staschko R, Fuchs N, Kästner M (2017) Simulation of self-piercing rivetting processes in fibre reinforced polymers: material modelling and parameter identification. J Mater Process Tech 241:164–177

    Article  Google Scholar 

  20. Xiong F, Wang D, Ma Z, Lv T, Ji L (2018) Lightweight optimization of the front end structure of an automobile body using entropy-based grey relational analysis. Proc Inst Mech Eng Part D: J Automob Eng 233(4):917–934

    Article  Google Scholar 

  21. Wang D, Wang S (2019) Multi-objective lightweight design of the container S-beam based on MNSGA-II with grey relational analysis. Proc Inst Mech Eng C J Mech Eng Sci 233(10):3376–3387

    Article  Google Scholar 

  22. Xie C, Wang D (2020) Multi-objective cross-sectional shape and size optimization of S-rail using hybrid multi-criteria decision-making method. Struct Multidiscip O 62:3477–3492

    Article  Google Scholar 

  23. Li S, Zhang S, Li H, Qin X, Wu X, Gui L (2022) Numerical and experimental investigation of fitting tolerance effects on bearing strength of CFRP/Al single-lap blind riveted joints. Compos Struct 281:115022

  24. Xu G, Cheng H, Zhang K, Liang B, Cheng Y, Hu J, Liu C (2020) Modeling of damage behavior of carbon fiber reinforced plastic composites interference bolting with sleeve. Mater Design 194:108904

  25. Han F, Yan Y, Ma J (2018) Experimental study and progressive failure analysis of stitched foam-core sandwich composites subjected to low-velocity impact. Polym Compos 39(3):624–635

    Article  Google Scholar 

  26. Zhou S, Yang C, Tian K, Wang D, Sun Y, Guo L, Zhang J (2019) Progressive failure modelling of double-lap of composite bolted joints based on Puck’s criterion. Eng Fract Mech 206:233–249

    Article  Google Scholar 

  27. Mandal B, Chakrabarti A (2018) Numerical failure assessment of multi-bolt FRP composite joints with varying sizes and preloads of bolts. Compos Struct 187:169–178

    Article  Google Scholar 

  28. Jiang H, Hong Z, Li G, Cui J (2020) Numerical and experiment investigation on joining process and failure behaviors of CFRP/Al electromagnetic riveted joint. Mech Adv Mater Struct 29(14):1996–2007

    Article  Google Scholar 

  29. Ma Y, Lou M, Li Y, Lin Z (2018) Modeling and experimental validation of friction self-piercing riveted aluminum alloy to magnesium alloy. Weld World 62(6):1195–1206

    Article  Google Scholar 

  30. Liu Y, Zhuang W, Luo Y, Xie D, Mu W (2023) Joining mechanism and damage of self-piercing riveted joints in carbon fibre reinforced polymer composites and aluminium alloy. Thin Wall Struct 182:110233

  31. Hassanifard S, Adibeig M, Mohammadpour M, Varvani-Farahani A (2019) Fatigue life of axially loaded clamped rivet-nut joints: experiments and analyses. Int J Fatigue 129:105254

  32. Xue Z, Wang X, Xu C, Chen Z, Feng X, Zhou Q, Liu J, Li L (2023) Equivalent characterization of pre-strained material properties and mechanical behavior prediction of steel/aluminum self-piercing riveted joints. Thin Wall Struct 182:110243

  33. Ying L, Gao T, Dai M, Hu P, Dai J (2021) Towards joinability of thermal self-piercing riveting for AA7075-T6 aluminum alloy sheets under quasi-static loading conditions. Int J Mech Sci 189:105978

  34. Huang L, Wu Y, Huff G, Huang S, Ilinich A, Freis A, Luckey G (2018) Simulation of self-piercing rivet insertion using smoothed particle Galerkin method. 15th Int LS-DYNA Users Conf

  35. Li D, Chrysanthou A, Patel I, Williams G (2017) Self-piercing riveting-a review. Int J Adv Manuf Technol 92(5–8):1777–1824

    Article  Google Scholar 

  36. Wang D, Li S (2021) Material selection decision-making method for multi-material lightweight automotive body driven by performance. Proc Inst Mech Eng Part L: J Mater: Des Appl 236(4):1–17

    MathSciNet  Google Scholar 

Download references

Funding

This work was supported by the National Natural Science Foundation of China (number 51975244).

Author information

Authors and Affiliations

  1. State Key Laboratory of Automotive Simulation and Control, Jilin University, Changchun, 130022, Jilin, People’s Republic of China

    Dewen Kong, Dengfeng Wang, Chong Xie, Xiaopeng Zhang & Zifeng Zhang

  2. China Fire and Rescue Institute, Beijing, People’s Republic of China

    Shuang Wang

Authors
  1. Dewen Kong
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Dengfeng Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Chong Xie
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Shuang Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Xiaopeng Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Zifeng Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Dewen Kong: methodology, experiments, software, and paper writing. Dengfeng Wang: funding acquisition. Chong Xie: methodology and software. Shuang Wang: software. Xiaopeng Zhang: validation. Zifeng Zhang: experiments.

Corresponding author

Correspondence to Dengfeng Wang.

Ethics declarations

Ethics approval and consent to participate

All authors participated in the research work.

Consent for publication

All authors consent to publish.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kong, D., Wang, D., Xie, C. et al. Investigation and optimization of structural parameters for the forming quality and mechanical properties of CFRP/Al self-piercing riveting. Int J Adv Manuf Technol 127, 3297–3313 (2023). https://doi.org/10.1007/s00170-023-11627-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11627-3

Keywords

Search

Navigation