Investigation of SPR Mechanical Performance with Aluminum Alloy Sheet

Abstract

In this paper, the technology of self-piercing riveting (SPR) with half-hollow rivets was investigated using experiments and numerical simulations with 6063 aluminum alloy sheet. The failure mechanism of SPR aluminum alloy sheet was indicated with the shear model and tear model, which could accurately simulate the sheet structure. Based on the simulation results with finite element method (FEA), the effect of die geometry on static mechanical characteristics, including punch load, failure load and failure displacement, was analyzed. It was discovered that the die pip height and sheet thickness should be designed synthetically for optimal tensile behavior.

Self-piercing riveting of aluminum alloy and thermoplastic composites

“…Hence SPR process has been proven to be a feasible alternative to spot welding for joining assemblies, especially for assemblies made in aluminum alloys. [11][12][13] During SPR process, the materials to be jointed are stacked together, with a punch above and a die underneath. When impacted by the punch, the rivet fully pierces the top panel and partially pierces the bottom panel.…”

“…Compared with spot welding, SPR is environmentally more friendly due to the low energy cost, low noise, and absence of fume and melting, which can effectively prevent introduction of discrepancies. [11][12][13][14] During SPR process, the large amount of plastic deformation can also introduce cracks into the riveted structure if the materials are brittle and have limited formability, leading to deteriorating of joint quality. 15,16 Recently, with the growing demand of lightweight materials and their manufacturing techniques, SPR technique for joining of composites and aluminum alloys has drawn more and more attention.…”