Abstract

As a result of lightweight design, increased use is being made of high-strength steel and aluminium in car bodies. Self-piercing riveting is an established technique for joining these materials. The dissimilar properties of the two materials have led to a number of different rivet geometries in the past. Each rivet geometry fulfils the requirements of the materials within a limited range. In the present investigation, an improved rivet geometry is developed, which permits the reliable joining of two material combinations that could only be joined by two different rivet geometries up until now. Material combination 1 consists of high-strength steel on both sides, while material combination 2 comprises aluminium on the punch side and high-strength steel on the die side. The material flow and the stress and strain conditions prevailing during the joining process are analysed by means of numerical simulation. The rivet geometry is then improved step-by-step on the basis of this analysis. Finally, the improved rivet geometry is manufactured and the findings of the investigation are verified in experimental joining tests.

Highlights

  • The lightweight design of car bodies is leading to the increased use of high-strength steel and aluminium [1]

  • Two different rivet geometries have been necessary for Self-piercing riveting (SPR) joining of the two material combinations used in the present investigation

  • The present results summarise the development of an improved rivet geometry which permits both the material combinations under consideration to be reliably joined with just a single rivet geometry

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Summary

Introduction

The lightweight design of car bodies is leading to the increased use of high-strength steel and aluminium [1]. A punch presses a semi-tubular rivet into the sheets. The rivet pierces the sheet on the punch side and as the rivet flares, an interlock is created [5]. The central components of SPR are the rivet and the die. Steel is normally located on the punch side on account of its high strength and low ductility. In this case, the sheet on the punch side is pierced with a low level of deformation. The sheet on the punch side is pierced with a low level of deformation This results in a slug, which remains under the rivet

Releasing
Sampling of the material combinations and modelling of the joining process
Analysis of the process and improvement of the rivet geometry
Experimental verification of the simulation results
Findings
Summary and outlook

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