锻压技术

铸铝自冲铆接接头裂纹扩展行为研究及仿真预测

英文标题：Research and simulation prediction on crack propagation behavior for cast aluminum self-piercing riveting joints

作者：胡晓雅1 2 黄理2 3 陈秋任2 3 张净宜2 谭国笔2 张永发2 4 韩维建2 3 王显会1

单位：1. 南京理工大学 2. 长三角先进材料研究院 3. 南京工业大学 4. 重庆大学

关键词：铸铝自冲铆裂纹损伤 GISSMO损伤失效

分类号：TG938

出版年,卷(期):页码：2023,48(9):113-118

摘要：

为了研究铸铝在自冲铆接工艺中的裂纹扩展行为，以5754铝板和Aural2铸铝为搭接组合的自冲铆接接头为研究对象，通过中断试验近似还原了接头剖面裂纹产生的位置和裂纹形貌，讨论了自冲铆接过程中接头内部铸铝材料的裂纹扩展机制，并进行了仿真分析，开展了几何形貌和裂纹预测。结果表明，铸铝自冲铆接接头裂纹产生的位置主要有两处：一处位于自冲铆接接头底面与模具接触一侧，裂纹在铆钉刚接触下板时产生，随着铆钉压入而增多；另一处位于铆钉钉腿与上下板形成互锁处的下板铸铝材料上，裂纹在形成互锁过程中产生，随着铆钉下压不断增长。建立的基于GISSMO损伤失效的铆接仿真模型，仿真结果的形貌轮廓与试验剖面的几何形貌一致，单元损伤与接头裂纹一致，可以对接头剖面几何形貌和裂纹位置进行准确预测。

In order to study the crack propagation behavior of cast aluminum in self-piercing riveting process, for a self-piercing riveting joint composed of 5754 aluminum plate and Aural2 cast aluminum, the location of the crack in joint profile and the morphology of crack were approximately restored by interrupted experiments. Then, the crack propagation mechanism of cast aluminum material inside the joint during the self-piercing riveting process was discussed, and the simulation and analysis was conducted to predict the geometric morphology and crack. The results show that there are two main locations where the cracks of cast aluminum self-piercing riveting joints occur, one is located on the side where the bottom surface of the self-piercing riveting joint is in contact with the mold, and the cracks occur when the rivets just contact the lower plate, and increase as the rivets are pressed in. The other is on the cast aluminum material of the lower plate where the rivet legs interlock with the upper and lower plates, and the cracks occur during the interlocking process and continue to grow as the rivets are pressed down. The riveting simulation model based on GISSMO damage failure is established, the morphology and contour of the simulation results are consistent with the geometric morphology of the test section profile, and the unit damage is consistent with the joint crack, which can accurately predict the geometric morphology and crack location of the joint profile.

基金项目：

国家自然科学基金青年基金资助项目（52205377）；苏州市基础研究基金资助项目（SJC2022031）

作者简介：胡晓雅（1997-），女，硕士 E-mail：huxy@jitriamrd.com 通信作者：黄理（1989-），男，博士，研究员 E-mail： hli@jitriamrd.com

参考文献：

[1]李永兵，马运五，楼铭，等. 轻量化薄壁结构点连接技术研究进展 [J]. 机械工程学报, 2020, 56(6)：125-146.

Li Y B, Ma Y W, Lou M, et al, Advances in spot joining technologies of lightweight thinwalled structures [J]. Journal of Mechanical Engineering, 2020, 56(6)：125-146.

[2]Huang L, Lasecki J V, Guo H, et al. Finite element modeling of dissimilar metal selfpiercing riveting process [J]. SAE International Journal of Materials and Manufacturing, 2014, 7(3): 698-705.

[3]Huang L, Moraes J F C, Sediako D G, et al. Finiteelement and residual stress analysis of selfpierce riveting in dissimilar metal sheets [J]. Journal of Manufacturing Science and Engineering, 2017, 139(2)：021007.

[4]吴小丹. 铝钢异种金属SPR铆接工艺及裂纹形成机理研究 [D]. 上海：上海交通大学, 2016.

Wu X D. Research on the Process Parameters and Formation Mechanism of Cracks of Selfpiercing Riveting for Dissimilar Metals [D]. Shanghai：Shanghai Jiao Tong University, 2016.

[5]Neuser M, Kappe F, Busch M, et al. Joining suitability of cast aluminium for selfpiercing riveting [J]. IOP Conference Series: Materials Science and Engineering, 2021, 1157(1)：012005.

[6]Moraes J F C, Jordon J B, Su X, et al. Effect of process deformation history on mechanical performance of AM60B to AA6082 selfpierce riveted joints [J]. Engineering Fracture Mechanics, 2019, 209: 92-104.

[7]Zhao X, Meng D, Zhang J, et al. The effect of heat treatment on die casting aluminum to apply selfpierce riveting [J]. The International Journal of Advanced Manufacturing Technology, 2020, 109(9-12): 2409-2419.

[8]Hofmann M. Selfpierce riveting of materials with limited ductility investigated with the BaiWierzbicki damage model in GISSMO [A]. LSDYNA Forum [C]. Bamberg, 2016.

[9]Jckel M, Coppieters S, Hofmann M, et al. Mechanical joining of materials with limited ductility: Analysis of processinduced defects[A]. International ESAFORM Conference on Material Forming 2017 [C]. Dublin,2017.

[10]廖品翔,林建平,闵峻英，等.下板厚度对钢/铝自冲铆接接头单搭剪切强度的影响[J].锻压技术,2022,47(7):145-153.

Liao P X, Lin J P, Min J Y, et al. Influence of lower plate thickness on single lap shear strength of joint in steel and aluminum selfpiercing riveting[J]. Forging & Stamping Technology,2022,47(7):145-153.

[11]孔婕,邓璐璐,刘亿,等.基于GISSMO断裂准则的6016铝合金断裂行为研究[J].精密成形工程,2022,14(4):1-10.

Kong J, Deng L L, Liu Y, et al. Fracture behavior of 6016 aluminum alloy based on GISSMO criterion [J]. Journal of Netshape Forming Engineering, 2022,14(4): 1-10.

[12]梁宾,赵岩,赵清江,等.基于Gissmo失效模型的6016铝合金板材断裂行为研究及应用[J].机械工程学报,2019,55(18):53-62.

Liang B, Zhao Y, Zhao Q J, et al. On the prediction of failure in 6016 aluminum alloy sheet by Gissmo damage model [J]. Journal of Mechanical Engineering, 2019, 55(18):53-62.

服务与反馈：

【文章下载】【加入收藏】