A New Self-Piercing Riveting Process and Strength Evaluation

2005 ◽  
Vol 128 (2) ◽  
pp. 580-587 ◽  
Author(s):  
Bin Wang ◽  
Chuanyong Hao ◽  
Jinsong Zhang ◽  
Hongyan Zhang
Keyword(s):  
Automotive Applications ◽  
Tensile Shear ◽  
New Device ◽  
Aluminum Sheets ◽  
Resistance Spot Welds ◽  
Riveted Joints ◽  
New Process ◽  
Riveting Process ◽  
Electrical Motors ◽  
Cross Tension

Self-piercing riveting (SPR) has become an important alternative joining technique for the automotive applications of aluminum sheets. Most existing SPR machines use electrical motors to drive a rivet into the sheets. A significant amount of research has been conducted to improve an SPR joint’s strength by increasing the mechanical interlock. In this paper, a new process is presented using gunpowder to drive the riveting process. A joint formed using the new process has different geometric characteristics from one created using a conventional system. The tensile-shear, cross-tension, fatigue, and impact performances of self-piercing riveted joints using the new device are compared to those of spot-welded joints on aluminum sheets. The experiment has proven that the new SPR joints have provided a similar or higher strength than resistance spot welds.

Behavior and Quality Evaluation of Electroplastic Self-Piercing Riveting of Aluminum Alloy and Advanced High Strength Steel

2013 ◽  
Vol 135 (1) ◽  
Author(s):  
Ming Lou ◽  
YongBing Li ◽  
YaTing Li ◽  
GuanLong Chen
Keyword(s):  
Shear Strength ◽  
Aluminum Alloy ◽  
High Strength Steel ◽  
High Strength ◽  
Tensile Shear Strength ◽  
Advanced High Strength Steel ◽  
Tensile Shear ◽  
Cold Forming ◽  
Riveting Process ◽  
Cross Tension

The hybrid use of dissimilar lightweight materials, such as aluminum alloy and advanced high strength steel (AHSS), has become a critical approach to reduce the weight of ground transportation vehicles. Self-piercing riveting (SPR) as a preferred cold-forming fastening method is facing problems like weak interlocking and insufficient penetration, due to the reduced formability of AHSS. In this paper, a new process named electroplastic self-piercing riveting (EP-SPR) was proposed to reduce the deformation resistance of AHSS DP780, by applying a direct current (dc) to it during the riveting process. The influence of dc on force and displacement characteristics throughout the riveting process, joint physical attributes and quasi-static performances for two sheet combinations, e.g., AA6061-T6 to DP780 (combination 1) and DP780 to AA6061-T6 (combination 2), were studied and compared with the traditional SPR joints. The results showed that compared with the traditional SPR joints, the EP-SPR ones increased by 12.5% and 23.3% in tensile-shear strength and cross-tension strengths for combination 1, respectively. For combination 2, even though the EP-SPR joints decreased by 5.8% in tensile-shear strength, it could reduce the penetration risk of bottom AA6061-T6, and present a better energy absorption capability for the increased undercut amount. In addition, the corresponding cross-tension strength of EP-SPR joints still increases by 6.1%.

Improving Fatigue Life of Riveted Joints by Rivet Hole Sizing

2014 ◽  
Vol 598 ◽  
pp. 141-146
Author(s):  
Adam Lipski ◽  
Zbigniew Lis
Keyword(s):  
Fatigue Life ◽  
Fold Increase ◽  
Fatigue Tests ◽  
Aviation Industry ◽  
Lap Joint ◽  
Riveted Joints ◽  
Riveting Process ◽  
The Difference ◽  
Structural Connection ◽  
The Impact

The aim of this paper is to assess the impact of the rivet hole sizing process on the fatigue life based on the example of the structural connections characteristic for riveted joints used in aviation industry. Test specimens reflected the structural connection consisting in a riveted lap joint of an airplane plating stiffened with a T-bar. Connected plates and the T-bar are made of D16CzATW aluminum alloy. 3 mm diameter oval head solid rivets for aviation-related purposes were made of PA24 aluminum. During fatigue tests, individual specimens with non-sized holes and with sized holes were subjected to uniaxial, one-sided, fixed-amplitude loading (R = 0). It can be concluded from the fatigue life comparison that introduction of an additional operation in the riveting process, i.e. the hole sizing, results in significant, about two-fold increase of the fatigue life of the riveted structural connection, even at slight sizing degree. The difference of the specimen damage nature was observed between specimens with sized and non-sized holes.

scholarly journals A Quality Study of a Self-Piercing Riveted Joint between Vibration-Damping Aluminum Alloy and Dissimilar Materials

2020 ◽  
Vol 10 (17) ◽  
pp. 5947
Author(s):  
Dong Hyuck Kam ◽  
Taek Eon Jeong ◽  
Jedo Kim
Keyword(s):  
Aluminum Alloy ◽  
Failure Modes ◽  
Mechanical Performance ◽  
Dissimilar Materials ◽  
Vibration Damping ◽  
Shear Load ◽  
Load Testing ◽  
Tensile Shear ◽  
Reinforced Plastic ◽  
Riveted Joints

This study investigates the quality of self-piercing riveted joints between vibration-damping aluminum (Al) and other dissimilar materials, namely aluminum alloy (AL5052-H32), steel alloy (GA590DP), and carbon-reinforced plastic (CFRP). The effects of die types (flat, cone, and nipple) on the geometrical characteristics and mechanical performance of the joints are studied using a cross-section examination and tensile shear load testing. The failure modes of each joint are also presented, showing the nature of the forces leading to the joint failures. The results indicate that, for all configurations, adequate joining between vibration-damping Al with AL5052-H32 is expected with a maximum shear load up to 3.28 kN. A shear load up to 3.6 kN was measured for the joints with GA590DP panels with acceptable top and bottom seal characteristics. A vibration-damping Al panel can only be positioned at the bottom when riveting with CFRP due to the brittle nature of CFRP. A tensile shear load up to 2.26 kN was found, which is the lowest amongst the materials tested in this study.

Effect of Geometric Parameters in the Upsetting and Extruding Riveting Process on the Quality of Riveted Joints

2015 ◽  
Vol 651-653 ◽  
pp. 1439-1444 ◽  
Author(s):  
Wei Jia Li ◽  
Lian Fa Yang
Keyword(s):  
Hole Diameter ◽  
Geometric Parameters ◽  
Hole Wall ◽  
Riveted Joints ◽  
Riveting Process ◽  
Simulation Results

Upsetting and extruding riveting is a new joining method, which is mainly used to join castings. In order to investigate the effect of geometric dimensions of punch and upper sheet hole diameter on the quality of joints, models with different geometric parameters were simulated via ABAQUS. According to the simulation results, the riveting process could be divided into five stages. Besides, diameter difference on rivet tail and interference value on upper sheet hole wall were selected as indicators to evaluate quality of joints. And a group of parameters is obtained for a better quality of joints. Finally, the simulation results were validated through experiments.

scholarly journals Microstructuring of joining areas in aluminum alloy sheets by Jet Electrochemical Machining

2018 ◽  
Vol 1 (2) ◽  
Author(s):  
Rene Schimmelpfennig ◽  
Matthias Hackert-Oschätzchen ◽  
André Martin ◽  
Andreas Schubert
Keyword(s):  
Shear Strength ◽  
Aluminum Alloy ◽  
Ultrasonic Vibration ◽  
Cross Sections ◽  
Electrochemical Machining ◽  
Limited Area ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Aluminum Sheets ◽  
Jet Electrochemical Machining

In this work the increase of the tensile shear strength by means of microstructuring of the metallic part for ultrasonic vibration assisted joining of hybrid compounds is presented. The aluminum alloy EN AW-5083 and a carbon fibre-reinforced plastic (CFRP) from Bond Laminates are used as a material combination. A suitable method is electrochemical processing (ECM). The microstructuring is carried out with continuous electrolyte free jet machining (Jet-ECM): Characteristic of this technology is the restriction of the electric current to a limited area of the electrolyte jet. After describing the materials and sample geometry used, the Jet-ECM technology and the ultrasonic vibration assisted joining process are explained. The strength of the joint is assessed by means of a tensile shear test. The determined results of the tensile shear strength for hybrid connections between microstructured aluminum sheets and CFRP are compared with those of unstructured aluminum sheets. Furthermore, the influence of the microstructure on the tensile shear strength achieved is discussed using metallographic cross-sections of the joining area.

scholarly journals Experimental Validation of Riveting Process Fe Simulation

2018 ◽  
Vol 2018 (10) ◽  
pp. 63-72
Author(s):  
Wojciech Wronicz
Keyword(s):  
Material Model ◽  
Fatigue Behaviour ◽  
Point Of View ◽  
Stress System ◽  
Critical Areas ◽  
Fe Simulations ◽  
Riveted Joints ◽  
The Press ◽  
Riveting Process ◽  
Force Displacement

Abstract Rivets are critical areas in metal airframes from the fatigue point of view. Fatigue behaviour of riveted joints depends strongly on the residual stress system around the rivet holes. The both most convenient and most common method of determining these stresses is the Finite Element (FE) analyses. The validation of models used is necessary to ensure the reliability of results. This paper presents the validation process of the riveting FE simulations for the universal and the countersunk rivets. At first, the material model of the rivets was validated with the use of the force–displacement curves of the press stamp obtained experimentally. Because of the displacement measurement method, it was necessary to take into account the flexibility of the stand. After that, good correlation between the numerical simulations and the experiment was obtained for both rivet types. At the second stage, strains around driven heads measured with the use of strip gauge patterns were compared with the results of the FE simulations. Quite good correlation was obtained for the countersunk rivet. In the case of the universal rivet, the numerical results are significantly higher values than the measured ones. Differences in correlation of the experiments and FE simulations for the analysed rivet types probably result from material differences of the rivets.

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