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<p>Self-piercing riveting (SPR) technology has been widely used in the automotive industry due to its high degree of automation, excellent joint sealing and fatigue resistance. In this paper, the forming process of SPR and the influence of process parameters on joint quality were investigated in detail through numerical simulation. To accurately capture the deformation and failure behavior of the sheet metal during SPR process, especially under relatively low stress triaxiality, a shear modified GTN damage model proposed by Nahshon and Hutchinson was adopted, and the corresponding numerical implementation method was developed. The damage related parameters were calibrated using a combination of the response surface method and the genetic algorithm. Subsequently, a three-dimensional explicit finite element model for SPR was established, and its validity was verified by comparing the cross-sectional dimensions of the joint with experiment results. The riveting process and damage evolution of the sheet metal were fully analyzed. Furthermore, the riveting process under different sheet stacking sequences, die types and depths was discussed. Specifically, when a thicker sheet is used as the lower sheet, it is conducive to achieving a larger under-cut and residual bottom thickness, with under-cut increasing by 9.5% and residual bottom thickness by 34.3% compared to the reverse configuration. Compared with a convex-bottom die, the use of a flat-bottom die significantly increases the under-cut of the joint by approximately 51.6%, while the residual bottom thickness and damage degree of the upper sheet are reduced by 34.1% and 11.2% respectively. When the die depth is increased&#xa0;from 1.8&#xa0;mm to 2.2&#xa0;mm, the high-stress area of the rivet leg decreases, whereas the damage degree of the upper sheet increases by 7.9%,&#xa0;accompanied by a 29.3% increase in residual bottom thickness and an 8.6% decrease in under-cut.</p>

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Study on forming mechanism of self-piercing riveting based on shear modified GTN damage model

  • 期刊论文

  • 发表日期：

    2026年2月24日

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  • Wenquan Liu,
  • Weilin Sun,
  • Dawei Chen

摘要

Self-piercing riveting (SPR) technology has been widely used in the automotive industry due to its high degree of automation, excellent joint sealing and fatigue resistance. In this paper, the forming process of SPR and the influence of process parameters on joint quality were investigated in detail through numerical simulation. To accurately capture the deformation and failure behavior of the sheet metal during SPR process, especially under relatively low stress triaxiality, a shear modified GTN damage model proposed by Nahshon and Hutchinson was adopted, and the corresponding numerical implementation method was developed. The damage related parameters were calibrated using a combination of the response surface method and the genetic algorithm. Subsequently, a three-dimensional explicit finite element model for SPR was established, and its validity was verified by comparing the cross-sectional dimensions of the joint with experiment results. The riveting process and damage evolution of the sheet metal were fully analyzed. Furthermore, the riveting process under different sheet stacking sequences, die types and depths was discussed. Specifically, when a thicker sheet is used as the lower sheet, it is conducive to achieving a larger under-cut and residual bottom thickness, with under-cut increasing by 9.5% and residual bottom thickness by 34.3% compared to the reverse configuration. Compared with a convex-bottom die, the use of a flat-bottom die significantly increases the under-cut of the joint by approximately 51.6%, while the residual bottom thickness and damage degree of the upper sheet are reduced by 34.1% and 11.2% respectively. When the die depth is increased from 1.8 mm to 2.2 mm, the high-stress area of the rivet leg decreases, whereas the damage degree of the upper sheet increases by 7.9%, accompanied by a 29.3% increase in residual bottom thickness and an 8.6% decrease in under-cut.