Effects of the die parameters on the self-piercing riveting process

Abstract

To facilitate the die selection for new self-piercing riveting (SPR) joint configurations, it is necessary to find out how the critical die geometric parameters influence the SPR process. In this study, a two-dimensional (2D) axisymmetric simulation model was developed to numerically study the riveting process. The influences of the die type, the die diameter, the die depth, and the die pip height on the deformation behaviour of the rivet and sheets were systematically studied. Moreover, the flared rivet shank radius and the thickness at the centre of the bottom sheet during the SPR process were first monitored using the developed simulation model. The simulation results revealed that these die parameters have significant influences on the deformation behaviour of the rivet and sheets. The flared rivet shank radius showed an increasing trend with the increment of the die diameter and the die pip height, while it decreased with the increment of the die depth. Furthermore, it was also found that the flaring speed of the rivet shank depended heavily on the filling condition of the die cavity underneath the rivet cavity. A rapid flare of the rivet shank was observed when this space was fully filled.