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Strength modeling of Al-alloy sheet self-piercing riveting considering different failure modes

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Abstract

Self-piercing riveting (SPR) is an efficient joining process for bonding sheets through the interlock of rivet flaring. The strength of SPR joints is commonly measured by destructive test. In this study, the metal deformation behaviors in the SPR of aluminum alloy sheets and the mechanical behaviors of the SPR joints in the destructive tests were investigated in order to develop the general strength models of SPR joints. As the important feature in the SPR process, the rivet flaring was quantified by an empirical estimator and utilized to establish the general strength models considering the geometric dimensions of components and tools, the material properties of rivet and sheets, and the load–displacement curve of punch. The predicted strengths of the SPR specimens were verified by the experimental results. All the calculation errors are lower than 8%. Finally, an industrial internet of things (IIoT) was developed to realize the data processing and the SPR joint strength predication.

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Abbreviations

t 0 :

The height of rivet head (mm)

t 1 :

Thickness of top sheet (mm)

t 2 :

Thickness of bottom sheet (mm)

L :

Rivet length (mm)

D h :

Diameter of rivet head (mm)

R r :

Rivet radius (mm)

H :

Rivet hardness (HV)

D d :

Diameter of flat die (mm)

h :

Depth of flat die (mm)

t eff :

Effective length of rivet in bottom sheet (mm)

t h :

Effective thickness of head-side material (mm)

D t :

Diameter of deformed rivet (mm)

d 0 :

Mmpunch displacement before rivet flaring (mm)

d max :

Maximum punch displacement (mm)

C 1 :

Coefficient depends on rivet length (0 ≤ C1 ≤ 1)

C2 :

Coefficient depends on rivet hardness (0 ≤ C2 ≤ 1)

η t :

Empirical coefficient of material degradation

β t :

Empirical coefficient of sheet thickness reduction

σ h :

Yield strength of heat-side sheet (MPa)

σ t :

Yield strength of tail-side sheet (MPa)

Δd :

Rivet flaring (mm)

α CT :

Empirical coefficient for cross-tension

α LS :

Empirical coefficient for lap-shear

a t :

Empirical coefficient for cross-tension in failure mode I

a h :

Empirical coefficient for cross-tension in failure mode II

b t :

Empirical coefficient for lap-shear in failure mode I

b h :

Empirical coefficient for lap-shear in failure mode II

F t CT :

Cross-tension strength in failure mode I (N)

F h CT :

Cross-tension strength in failure mode II (N)

F t LS :

Lap-shear strength in failure mode I (N)

F h LS :

Lap-shear strength in failure mode II (N)

FCT :

Cross-tension strength (N)

FLS :

Lap-shear strength (N)

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Authors and Affiliations

  1. School of Materials Science and Engineering, Shanghai Jiao Tong University, No. 800, Dongchuan Road, Shanghai, 200240, China

    Yahui Liu, Zhiwang Zhu, Huipeng Yu & Jun Wang

  2. Shanghai Key Laboratory of Advanced High-Temperature Materials and Precision Forming, Shanghai Jiao Tong University, 800 Dongchuan Road, Minhang District, Shanghai, 200240, China

    Yahui Liu & Jun Wang

  3. State Key Laboratory of Metal Matrix Composites, Shanghai Jiao Tong University, 800 Dongchuan Road, Minhang District, Shanghai, 200240, China

    Jun Wang

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  4. Jun Wang
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Yahui Liu, Zhiwang Zhu, Huipeng Yu, and Jun Wang. The first draft of the manuscript was written by Yahui Liu and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Yahui Liu or Jun Wang.

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Liu, Y., Zhu, Z., Yu, H. et al. Strength modeling of Al-alloy sheet self-piercing riveting considering different failure modes. Int J Adv Manuf Technol 127, 2487–2503 (2023). https://doi.org/10.1007/s00170-023-11635-3

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