A framework for calibration of self-piercing riveting process simulation model

Fang, Yudong; Huang, Li; Zhan, Zhenfei; Huang, Shiyao; Liu, Xiongjie; Chen, Qiuren; Zhao, Hailong; Han, Weijian

doi:10.1016/j.jmapro.2022.01.015

Cited by 16 publications

(4 citation statements)

References 21 publications

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“…Sobol sensitivity analysis is widely used in various fields in the industry to identify the most critical input variables and improve the accuracy and robustness of models. It was employed to quantify the impact of input variables on the output of a model or simulation and provided a measure of the relative importance of each input variable by decomposing the total variance in the model output into contributions [30,31]. Herein, the Sobol sensitivity analysis method was employed to investigate the effects of curing profile parameters on the results.…”

Section: Parameter Sensitivity Analysismentioning

confidence: 99%

Sensitivity Analysis and Multi-Objective Optimization Strategy of the Curing Profile for Autoclave Processed Thick Composite Laminates

2023

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To mitigate the risk of manufacturing defects and improve the efficiency of the autoclave-processed thick composite component curing process, parameter sensitivity analysis and optimization of the curing profile were conducted using a finite element model, Sobol sensitivity analysis, and the multi-objective optimization method. The FE model based on the heat transfer and cure kinetics modules was developed by the user subroutine in ABAQUS and validated by experimental data. The effects of thickness, stacking sequence, and mold material on the maximum temperature (Tmax), temperature gradient (ΔT), and degree of curing (DoC) were discussed. Next, parameter sensitivity was tested to identify critical curing process parameters that have significant effects on Tmax, DoC, and curing time cycle (tcycle). A multi-objective optimization strategy was developed by combining the optimal Latin hypercube sampling, radial basis function (RBF), and non-dominated sorting genetic algorithm-II (NSGA-II) methods. The results showed that the established FE model could predict the temperature profile and DoC profile accurately. Tmax always occurred in the mid-point regardless of laminate thickness; the Tmax and ΔT increased non-linearly with the increasing laminate thickness; but the DoC was affected slightly by the laminate thickness. The stacking sequence has little influence on the Tmax, ΔT, and DoC of laminate. The mold material mainly affected the uniformity of the temperature field. The ΔT of aluminum mold was the highest, followed by copper mold and invar steel mold. Tmax and tcycle were mainly affected by the dwell temperature T2, and DoC was mainly affected by dwell time dt1 and dwell temperature T1. The multi-objective optimized curing profile could reduce the Tmax and tcycle by 2.2% and 16.1%, respectively, and maintain the maximum DoC at 0.91. This work provides guidance on the practical design of cure profiles for thick composite parts.

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Section: Parameter Sensitivity Analysismentioning

confidence: 99%

Sensitivity Analysis and Multi-Objective Optimization Strategy of the Curing Profile for Autoclave Processed Thick Composite Laminates

2023

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“…Periodic increases in fuel prices are also a factor of concern in reducing automobile weight for the world's countries. In these contexts, research works have focused on introducing automobiles with novel structures that are lightweight in nature [3,4]. The processing of novel materials and the production of structures are not possible without the effective contribution of processing techniques.…”

Section: Introductionmentioning

confidence: 99%

Self-Pierce Riveting: Development and Assessment for Joining Polymer—Metal Hybrid Structures in Lightweight Automotive Applications

Sankaranarayanan,

Hynes,

Nikolova

et al. 2023

Polymers

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In recent years, the transportation industry has faced the challenge of cutting costs, meeting increasingly stringent environmental regulations, and significantly increasing transportation volumes. One approach to meeting these challenges is to develop new, improved transportation vehicles using new materials and innovative joining techniques. Multi-material structures are becoming an alternative to body parts. Self-pierce riveting technology plays a crucial role in this process, and hybrid structures depend exclusively on it. In this article, recent advances in self-pierce riveting technology are analyzed to meet today’s challenges and future multi-material applications.

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“…With the increasing demand for lightweight technology in the automotive manufacturing industry, the use of lightweight materials such as carbon fiber reinforced plastic (CFRP) and aluminum alloys (Al) in vehicle bodies is rapidly increasing. 1,2 Since resistance spot welding will bring about changes in material properties during the local heating process, 3 for example, the epoxy resin of CFRP will be damaged under high temperature environment, and Al will suffer from electrode wear, porosity, and splash during the heating process. 4 Therefore, the traditional welding technology cannot meet the connection requirements between CFRP and Al, this poses a new challenge to the current connection technology.…”

Section: Introductionmentioning

confidence: 99%

Study on the forming process and shear mechanical behavior of CFRP/Al self-piercing riveting employed 3D modeling

Kong

Wang

Zhang

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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In this work, a 3D finite-element model (FEM) was developed to accurately predict the mechanical behavior of CFRP/Al self-piercing riveting (SPR) during the forming and shearing process. A continuous damage model based on the modified Hashin failure criterion was proposed to model the CFRP, and a cohesive model considering the traction-separation criterion was used to capture the delamination between CFRP layers. The simulation results were in good agreement with the experimental results. Based on the developed FEM, the damage of CFRP in the SPR forming process, the shear mechanical properties and damage of joints in the SPR shearing process, the effects of CFRP plate thickness and rivet length on the SPR forming cross-section and shear strength were investigated. The results showed that, the maximum interlock value of 0.46 mm was obtained when the rivet length was 6.5 mm and the CFRP plate thickness was 1.6 mm. The maximum shear peak load of 3611.98 N was obtained when the rivet length was 6.5 mm and the CFRP plate thickness was 2.2 mm. The interaction between rivet length and CFRP plate thickness should be considered in the actual SPR connection.

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A framework for calibration of self-piercing riveting process simulation model

Cited by 16 publications

References 21 publications

Sensitivity Analysis and Multi-Objective Optimization Strategy of the Curing Profile for Autoclave Processed Thick Composite Laminates

Sensitivity Analysis and Multi-Objective Optimization Strategy of the Curing Profile for Autoclave Processed Thick Composite Laminates

Self-Pierce Riveting: Development and Assessment for Joining Polymer—Metal Hybrid Structures in Lightweight Automotive Applications

Study on the forming process and shear mechanical behavior of CFRP/Al self-piercing riveting employed 3D modeling

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