Continuous Numerical Analysis of Slug Rivet Installation Process Using Parameterized Modeling Method

The slug rivet installation process is complex. A lot of parameters are included during the riveting deformation process. The workload and time cost of a traditional simulation study is very high since a traditional numerical model should be modified manually time by time when riveting parameters change. The data processing after simulation is another complex work. To improve the situation, this paper presents a parameterized modeling method. The modeling process and data processing algorithm can be developed using Python script. The parameterized model can automatically and continuously re-build without any manual intervention according to the riveting parameter auto-update condition. The post-processing analysis can be automatically conducted and saved as well. Then this paper conducts continuous analysis to illustrate the impact of riveting parameters on riveting quality. The parameterized model keeps running 41 times until the riveting parameter is out of range. The parameterized modeling method is a useful method for a simulation study. The study will pave the way for further investigations.

Slug rivet assembly modeling and effects of procedure parameters on the quality of riveted lap joints

Slug rivet interference-fit riveting is one of the advanced connection technologies which has been widely applied in aerospace manufacture. This article presents an appropriate numerical model simulating the slug rivet upset process with countersunk hole structure. Many previous studies have focused on the riveted lap joints without countersunk hole structure and ignored its related process parameters. The main difference is that the hole expansion would be inhomogeneous through the thickness direction due to the impact of countersunk hole. To improve the riveting quality and reduce the inhomogeneity scale of the interference distribution, the effects of two procedure parameters have been assessed. The analysis results significantly improve knowledge about the slug rivet installation process as well as the effects of the corresponding process parameters. The study will pave the way for further investigations.

Investigation of Riveting Parameters Influence on the Riveted Joints Deformation During Slug Rivet Installation

Slug rivet is widely used in aircraft assembly due to the higher interference fit level and the longer fatigue life. However, the inhomogeneity of riveting interference value along the thickness direction of the aircraft panels always leads to inevitable deformation, which significantly degrades the dimensional accuracy of the final products. In this study, a quantitative model is established to describe the relationship between several riveting parameters (i.e. squeezing force, buck cavity, upsetting rise time, upsetting dwell time and clamping force between sheets) and the deformation of a formed slug rivet joint. Then the coefficient of variance (CV) is introduced to evaluate the homogeneity of deformation. Subsequently, an optimized combination of the presented parameters is obtained by using finite element method (FEM) simulation so as to generate more uniform deformation. Finally, the FEM model is validated by a series of orthogonal experiments conducted in G86 fully automated C-frame riveting machine and the results show that the squeezing force and the buck cavity are the main significant factors and contributors to the riveted joints deformation, and the sequence of this effect from the high to low are: upsetting dwell time, clamping force, and upsetting rise time. The results also indicate that the developed FE model can be used for further analysis, including the prediction of large component riveting deformation and the mechanical properties of riveted joint.

Finite Element Analysis of Axis Deviation between Rivet and Plate Hole

The riveting joint is the main connection method in aircraft assembly. There are some kind of rivets, such as slug rivet and protruding rivet, that riveting quality will be impacted while rivets axis are not coincident with the plate holes axis. By using the finite element method with ABAQUS software, this paper built the 3D riveting joint structure of finite element, and analyzed the axis deviation effect on the deformation, stress and strain of riveting. Through statistical data, the relationship among axis deviation value, deformation, stress and strain of rivet are built.