Transactions of Materials and Heat Treatment

Title：Numerical simulation study on forming quality for steel/aluminium sheet by self-piercing riveting and pre-punched self-piercing riveting

Authors： Yu Wanyuan1 Wang Chao2 Chen Tao2 Tan Hailun2

Unit： (1. College of Automotive Engineering Liuzhou Vocational & Technical College Liuzhou 545001 China 2. State Key Laboratory of Advanced Design and Manufacture for Vehicle Body Hunan University Changsha 410082 China)

KeyWords： steel/aluminum sheet conventional self-piercing riveting pre-punched self-piercing riveting forming quality undercut value

ClassificationCode：TG938

year,vol(issue):pagenumber：2025,50(4):183-194

Abstract：

The forming differences between conventional self-piercing riveting (C-SPR) and pre-punched self-piercing riveting (PH-SPR) in joining steel/aluminum sheets were compared and studied， and the influences of rivet hardness， geometric dimensions of rivets and dies， sheet material and thickness on the forming quality were analyzed. Then， a two-dimensional (2D) axisymmetric finite element model of the SPR riveting process was established by LS-DYNA， and the accuracy of the numerical model was validated by comparing the tested and simulated cross-sectional shape of the SPR joint. The results show that when the yield strength of rivet is 0.9~1.3 GPa， PH-SPR has a higher undercut value. At the same time， PH-SPR process needs to select a suitable rivet length to ensure the forming quality. The bottom thickness of C-SPR and PH-SPR joints is more significantly affected by the die size parameters than the undercut value. PH-SPR has higher versatility when connecting different material combinations， while C-SPR is only suitable for connecting sheet with a yield strength of less than 500 MPa.Both C-SPR and PH-SPR are suitable for connecting thinner upper sheets (thickness≤1.6 mm).

Funds：

基金项目:广西高校中青年教师科研基础能力提升项目(2024KY1097)；广西科技重大专项(桂科AA23062064)；湖南省自然科学基金资助项目(2023JJ40153)

作者简介：于万元(1987-)，女，硕士，工程师

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