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Research Papers

Modeling of Single-Sided Piercing Riveting Process

[+] Author and Article Information
Yuhong Liu

School of Mechanical Engineering, Tianjin University, Tianjin 300072, Chinayuhong_liu@tju.edu.cn, nwpulyh587@sina.com

Shuxin Wang, Lianhong Zhang, Rui Zhou, Weijing Liu

School of Mechanical Engineering, Tianjin University, Tianjin 300072, China

P. C. Wang

 General Motors Corporation, Warren, MI 48090

J. Manuf. Sci. Eng 132(2), 021013 (Apr 21, 2010) (7 pages) doi:10.1115/1.4001249 History: Received September 16, 2009; Revised February 03, 2010; Published April 21, 2010; Online April 21, 2010

The performance of adhesive bonded subassemblies and vehicle structures strongly depends on not only the properties of the adherends and adhesives but also the gap between the workpieces. An excessive gap between the joined structural elements could result in the joint strength decreased. In this study, a single-sided piercing riveting (SSPR) of workpieces was proposed and analyzed to ensure the part fit-up. The SSPR process has been modeled using the explicit finite element code LS-DYNA . A 3D model including the workpieces, rivet and riveting tools was generated. The model simulates the rivet piercing and deformation of 2 mm thick aluminum alloy AA5052. It was found that rivet speed and rivet leg chamfers are the main factors to influence the gap between the workpieces and consequently the quality of the riveted joints. To minimize the gap between the workpieces and optimizing the joint strength, proper riveting velocity and rivet leg chamfer are recommended.

Copyright © 2010 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Illustration of single-sided piercing rivet-bonding process:(1—upper sheet, 2—lower sheet, 3—adhesive, 4—gap, 5—supporting block, 6—cylinder, 7—piston rod, and 8—U-shaped staple)

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Figure 2

U-shaped staple and air staple gun: (a) U-shaped staple and (b) air staple gun

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Figure 3

The SSPR-bonded joint

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Figure 4

Physical model of SSPR

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Figure 5

3D FEM model for SSPR

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Figure 6

Solid164 element geometry (22)

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Figure 7

Single-sided piercing riveting of 2 mm thick AA5052 in various stages: (a) prior to impact the rivet, (b) piston rod hit the rivet, (c) piercing through upper sheet, and (d) piercing into lower sheet

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Figure 8

Comparison of the modeling calculations and experimental results: (a) modeling result and (b) experimental result

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Figure 9

Nodes selected for measuring the gap between the workpieces

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Figure 10

Variation in gap between the workpieces during modeling SSPR and the final gaps obtained from SSPR experimental

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Figure 11

Variation in kinetic energy of the rivet during SSPR

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Figure 12

Effect of riveting velocity on the gap in SSPR AA5052 aluminum

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Figure 13

Definition of rivet flare angle and leg chamfer

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Figure 14

Numerical-experimental comparison of flare angles for different rivet leg chamfers: (a) rivet leg chamfer is 55 deg and (b) rivet leg chamfer is 65 deg

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Figure 15

Effect of rivet leg chamfer on the flare angle of rivet legs

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Figure 16

Schematic of cross-section of riveted joint

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Figure 17

Calculated effect of riveting speed on the rivet penetration

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