Experimental and numerical assessment of self-pierce riveting of HIF steel and AA5083 sheets with fracture prediction

IF 6.6 1区工程技术 Q1 ENGINEERING, CIVIL Thin-Walled Structures Pub Date : 2025-05-01 Epub Date: 2025-01-14 DOI:10.1016/j.tws.2025.112959

Sai Harshith Badi , R Ganesh Narayanan , Brajesh Asati , Sudip Santra , Kanwer Singh Arora

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Abstract

The current work aims to understand the impact of rivet hardness, diameter and length, and bottom sheet thickness on the quality of Self-piercing rivet (SPR) joints using pip and flat dies. High-strength interstitial free (HIF) steel and AA5083 sheets are joined, with AA as the bottom sheet. Upper sheet fracture during SPR is predicted by a novel strain mapping method through the Shear Fracture Forming Limit Curve (SFFLC) and the existing Hosford-Coulomb fracture model (HC model) using Abaqus, along with experimental validation. Successful SPR joints between the sheets are possible only with a pip die. Rivet cracks and local rivet bending are observed for the flat die. Rivet hardness, rivet length, and bottom sheet thickness show synergistic effects on riveting force, shear fracture, and joint indices. As a result, using smaller rivets (3.35 mm diameter) along with a flat die is not recommended for the sheets, and the 5.3 × 6.0/pip/2/480 configuration is the best choice for joining HIF steel and AA5083. In the numerical prediction, riveting force and indices are predicted with acceptable error within experimental variations and accuracy levels available in the literature. Moreover, SFFLC and HC model-based fracture predictions are accurate; however, SFFLC is easy to implement with calibrated lab scale test data.

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HIF钢与AA5083板自穿孔铆接断口预测的试验与数值评价

目前的工作旨在了解铆钉硬度、直径和长度以及底板厚度对使用pip和扁平模具的自穿孔铆钉（SPR）连接质量的影响。采用高强度无间隙钢（HIF）与AA5083板连接，以AA为底层板。利用Abaqus，通过剪切断裂成形极限曲线（SFFLC）和现有的霍斯福-库仑断裂模型（HC模型），采用一种新的应变映射方法预测SPR过程中的上板断裂，并进行了实验验证。板材之间成功的SPR接头只有使用凸模才有可能。在平模中观察到铆钉裂纹和局部弯曲。铆钉硬度、铆钉长度和底板厚度对铆接力、剪切断口和接头指标具有协同效应。因此，不建议使用较小的铆钉（3.35 mm直径）和平模具，5.3 × 6.0/pip/2/480配置是连接HIF钢和AA5083的最佳选择。在数值预测中，铆接力和指标的预测在实验变化和文献中可用的精度水平范围内具有可接受的误差。此外，基于SFFLC和HC模型的裂缝预测是准确的；然而，SFFLC很容易实现校准实验室规模的测试数据。

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来源期刊

Thin-Walled Structures 工程技术-工程：土木

CiteScore

9.60

自引率

20.30%

发文量

801

审稿时长

66 days

期刊介绍： Thin-walled structures comprises an important and growing proportion of engineering construction with areas of application becoming increasingly diverse, ranging from aircraft, bridges, ships and oil rigs to storage vessels, industrial buildings and warehouses. Many factors, including cost and weight economy, new materials and processes and the growth of powerful methods of analysis have contributed to this growth, and led to the need for a journal which concentrates specifically on structures in which problems arise due to the thinness of the walls. This field includes cold– formed sections, plate and shell structures, reinforced plastics structures and aluminium structures, and is of importance in many branches of engineering. The primary criterion for consideration of papers in Thin–Walled Structures is that they must be concerned with thin–walled structures or the basic problems inherent in thin–walled structures. Provided this criterion is satisfied no restriction is placed on the type of construction, material or field of application. Papers on theory, experiment, design, etc., are published and it is expected that many papers will contain aspects of all three.