For self-piercing riveting of AA5052-H32 aluminum sheet with two layers of 2 mm thickness for automobile battery pack, the process parameters of self-piercing riveting were optimized by software DEFORM-2D and response surface method, and the mathematical relationship between process parameters and under-cut value was established with the help of central composite design and simulation results. The result shows that the interaction between die width and die depth has the greatest influence on the under-cut value. Therefore, taking die width, die depth and height of die convex as design variables and the under-cut value as the optimization objective of forming quality, the process parameters of self-piercing riveting for aluminum sheet were optimized by software Design Expert, and the optimized values were obtained with the die depth of 1.45 mm, the die width of 8.95 mm, the height of die convex of -0.15 mm, and the response value of under-cut of 0.609 mm. In addition, the optimization scheme was verified by riveting equipment, the experimental value of under-cut was 0.546 mm, and the relative error between experimental value and response value was 10.34%. Therefore, the accuracy and reliability of response surface method applied to the optimization of process parameters for self-piercing riveting of aluminum sheet were verified.