An experimental and numerical investigation of the role of rivet and die design on the self-piercing riveting joint characteristics of aluminum and steel sheets

We analyze the role of different rivet and die design parameters on feasibility quality self-piercing riveting (SPR) joining metallic sheet stacks. In particular, a similar aluminum-to?aluminum stack (AA2019/AA7075-F) dissimilar aluminum-to-steel (AA7075-F/BA0270) is investigated, both experimentally numerically. Towards this, materials are characterized to obtain their elastoplastic fracture attributes. Thereafter, SPR process finite element models developed. Initially, joint probed for specific available configurations, thus identifying that allow successful joining. wider range investigated It observed combination formation high interlock values obtained over ranges leg thickness depth values. Moreover, low near-unity normalized depths – with sum total respect length yield joints types stacks considered. However, optimum parameter selection stack-specific, high-quality AA2019/AA7075-F be feasible more constrained parametric space compared AA7075-F/BA0270 case. Further, it concluded mean von Mises stress induced in sheets after primarily affected by depth, being less sensitive other parameters, such as or shape cases.