Numerical modelling and experimental investigation of the Riv-Bonding process

Abstract

Nowadays, the Riv(et)-Bonding technique has become a major joining approach in the automotive industry. It effectively incorporates the benefits of the adhesive bonding and the self-pierce riveting (SPR), but overcomes their individual drawbacks. Finite element (FE) simulation of the SPR process now plays a very important role during the product design and manufacture processes in the automotive field. However, there is no reported progress in the simulation of the Riv-Bonding process. To deepen understandings of this joining method, a FE model of the Riv-Bonding process suitable for industrial applications was developed in this study. The Ostwald-de Waele power law was adopted to approximately represent properties of the adhesive SikaPower 498. Interrupted laboratory tests of the SPR process and the Riv-Bonding process were carried out to calibrate the FE model, and another eight types of joints were experimentally made to verify the effectiveness of the developed model. Meanwhile, the effects of the adhesive layer on the joint quality and the riveting process were analysed by comparing the interrupted test results of the two processes. The adhesive distribution during the Riv-Bonding process was also discussed. The developed model was proven capable of predicting the Riv-Bonding process, including the adhesive distribution, the solid parts deformation and the load-displacement curve. Unlike the SPR simulation, the blank-holder strike during the clamping stage should be properly modelled in the simulation model of the Riv-Bonding process, due to its noticeable influences on the adhesive distribution as well as on the top sheet deformation. It was also found that, under the studied joint configuration, the adhesive layer demonstrated slightly negative effects on the riveted connection of the Riv-Bonded joints. The simulation model developed in this study lays a foundation for further quality prediction and mechanical strengths modelling of the Riv-Bonded joints.