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Research Papers

Modeling of Friction Self-Piercing Riveting of Aluminum to Magnesium

[+] Author and Article Information
YunWu Ma, Ming Lou

State Key Laboratory of Mechanical
System and Vibration,
Shanghai Key Laboratory of Digital
Manufacture for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China

YongBing Li

Professor
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Key Laboratory of Digital
Manufacture for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: yongbinglee@sjtu.edu.cn

Wei Hu

Livermore Software Technology Corporation,
7374 Las Positas Road,
Livermore, CA 94551

ZhongQin Lin

Professor
State Key Laboratory of Mechanical
System and Vibration,
Shanghai Key Laboratory of Digital
Manufacture for Thin-Walled Structures,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China

1Corresponding author.

Manuscript received June 25, 2015; final manuscript received November 11, 2015; published online January 6, 2016. Assoc. Editor: Wayne Cai.

J. Manuf. Sci. Eng 138(6), 061007 (Jan 06, 2016) (9 pages) Paper No: MANU-15-1310; doi: 10.1115/1.4032085 History: Received June 25, 2015; Revised November 11, 2015

In recent years, higher requirements on vehicle performance and emission have been posing great challenges to lightweighting of vehicle bodies. Mixed use of lightweight materials, e.g., aluminum alloys and magnesium alloys, is one of the essential methods for weight reduction. However, the joining of dissimilar materials brings about new challenges. Self-piercing riveting (SPR) is a feasible process to mechanically join dissimilar materials, however, when magnesium alloy sheet is put on the bottom layer, cracks occur inevitably due to the low ductility of the magnesium alloy. Friction self-piercing riveting (F-SPR) process is a newly proposed technology, which combines the SPR with friction stir spot welding (FSSW) and has been validated being capable of eliminating cracks and improving joint performance. However, in the F-SPR process, the generation of the transient friction heat and its effect on interaction between the rivet and the two sheets are still unclear. In this paper, a three-dimensional thermomechanical-coupled finite-element (FE) model of F-SPR process was developed using an ls-dyna code. Temperature-dependent material parameters were utilized to calculate the material yield and flow in the joint formation. Preset crack failure method was used to model the material failure of the top sheet. The calculated joint geometry exhibited a good agreement with the experimental measurement. Based on the validated model, the transient formation of F-SPR mechanical joint, stress distribution, and temperature evolution were further investigated.

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Figures

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Fig. 1

Schematic of F-SPR process driven from inside of the rivet: (a) rivet feed, (b) rivet piercing, (c) hot riveting, (d) in situ friction, and (e) release

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Fig. 2

Schematic of F-SPR process driven from outside of the rivet: (a) rivet feed, (b) rivet piercing, (c) hot riveting, (d) in situ friction, and (e) release

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Fig. 3

Comparison of the cross section views of joints made using 1.0 mm thick AA6061-T6 and 2.2 mm thick AZ31B: (a) SPR and (b) F-SPR

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Fig. 4

Geometrical model construction: (a) F-SPR prototype and (b) geometrical model

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Fig. 5

Mesh strategy of F-SPR model: (a) three rigid bodies, (b) rivet, and (c) sheets

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Fig. 6

High-temperature tensile test: (a) close-up view of the Zwick/Roell Z050 material testing machine and (b) dimensions of the specimen

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Fig. 7

Sketch of the preset crack surface failure method

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Fig. 8

Final cross section profile of the F-SPR joints: (a) experimental [21] and (b) simulation

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Fig. 9

Geometrical features comparison between experiment and simulation

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Fig. 10

Von Mises stress and effective plastic strain distributions during the F-SPR process

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Fig. 11

Calculated rivet shank twist at the end of the F-SPR process

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Fig. 12

Highest temperature evolution of the sheets during the F-SPR process

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Fig. 13

Temperature distribution of the bottom sheet along the radial direction

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