Abstract
The present work aims for an initial computational simulation with finite element analysis of the friction riveting process. Knowledge and experimental data from friction riveting of AA2024-T351 and polyetherimide supported the computational simulation. Friction riveting is a friction-based joining technology capable of connecting multiple dissimilar overlapping materials in a fast and simple manner. In this paper, the plastic deformation of the metallic rivet, process heat input, and temperature distribution were modeled and simulated. The plastic deformation of the metallic rivet is of key importance in creating the mechanical interlocking and main joining mechanism between the parts, being this the focus of this work. The influence of the polymeric material was considered a dynamic boundary condition via heat input and pressure profiles applied to the rivet. The heat input, mainly generated by viscous dissipation within the molten polymer, was analytically estimated. Three experimental conditions were simulated. The heat flux values applied in modeling of the different conditions were determined (8.2, 9.1, and 10.2 W/mm2). These yielded distinct plastic deformations characterized by a diameter of the rivet tip, from the initial 5 mm to 6.2, 7.0, and 9.3 mm. The maximum temperatures were 365, 395, and 438 °C, respectively.
Highlights
The field of dissimilar and hybrid connections has nowadays a great importance for several industries, and it is continuously challenging the more traditional methods, e.g., mechanical fastening and adhesive bonding, for their applications
The present work was able to demonstrate that despite the assumptions and simplifications, it was possible to obtain a good correlation between the simulated plastic deformation of the metallic rivet and the experimental results of the joints produced
As a first investigation on modeling the friction riveting process, the results validated the use of the preliminary heat input model proposed in literature for the process, as a tool for estimating and simulating the energy being delivered to the rivet
Summary
The field of dissimilar and hybrid connections has nowadays a great importance for several industries, and it is continuously challenging the more traditional methods, e.g., mechanical fastening and adhesive bonding, for their applications. Given this growing interest for alternative joining technologies, it is ever more crucial to have deep knowledge regarding the processes on an experimental/practical level and being able to simulate the mechanisms present during those. Developed and patented by Helmholtz-Zentrum Geesthacht [1], this joining process consists of a rotating cylindrical metallic rivet being pressed against overlapping polymeric components, generating heat by friction and creating metallic insert spot joints. The heat generation depends on high shear rates, initially localized mostly in the polymer-based component, but arising to the metallic component in the later stages of the process
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