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Comparisons of formation process and quality between two-layer and three-layer self-piercing riveted joints

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Abstract

In this paper, the differences and similarities between two-layer and three-layer self-piercing riveting (SPR) joints were systematically analysed by combining experimental tests and a finite element (FE) model. The influences of top-to-middle sheet thickness ratio (r1) on the joining results of three-layer joints were also numerically investigated. It was found that, compared with the top sheet in two-layer joints, the split top and middle sheets in the corresponding three-layer joints underwent greater plastic deformation. The rivet shank experienced less plastic deformation, and the risk of shear fracture of the rivet shank was effectively reduced. When the r1 increased from 0 to infinity, the interlock (I1) always first increased then decreased and followed by an apparent increase within the studied range. The remaining bottom sheet thickness at the joint centre (tc) and under the rivet tip (ttip) showed opposite changing trends: the tc first increased and then decreased, whilst the ttip first decreased but then increased. The results also revealed that the experimental data of two-layer joints can be used to guide the design of three-layer joints: from the two-layer joints to corresponding three-layer joints, the I1 more likely achieves a greater value when the r1 < 1.0 but a smaller value when the r1 > 1.0, and a larger tc but a smaller ttip are more likely achieved regardless of the r1.

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Acknowledgements

The authors would like to thank Dr. Matthias Wissling, Paul Bartig and their team members from Tucker GmbH for their support during the laboratory tests.

Funding

This research is funded by Jaguar Land Rover.

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Authors and Affiliations

  1. College of Mechanical Engineering, Tianjin University of Science and Technology, Tianjin, 300222, China

    Huan Zhao

  2. Tianjin Key Laboratory of Integrated Design and On-line Monitoring for Light Industry & Food Machinery and Equipment, Tianjin, 300222, China

    Huan Zhao

  3. Hansher Consulting Ltd., Coventry, UK

    Li Han

  4. School of Engineering, University of Warwick, Coventry, CV4 7AL, UK

    Xianping Liu

  5. Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Yunpeng Liu

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  1. Huan Zhao
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection and analysis were performed by Huan Zhao and Yunpeng Liu. The first draft of the manuscript was written by Huan Zhao and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Yunpeng Liu.

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Zhao, H., Han, L., Liu, X. et al. Comparisons of formation process and quality between two-layer and three-layer self-piercing riveted joints. Int J Adv Manuf Technol 127, 4745–4767 (2023). https://doi.org/10.1007/s00170-023-11825-z

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