<p>The complex interplay of riveting process variables accentuates the nonlinear dynamics inherent in the riveting process, exercising a marked influence on the ultimate quality of the riveted assembly. This study aims to elucidate the interactive phenomena among the process variables during the riveting of carbon fiber-reinforced polymer composites to aluminum alloy sheets. An orthogonal array design was employed to orchestrate a series of simulations that encapsulate varying combinations of riveting process parameters. Subsequent to this, the developed simulation model was validated against empirical data. The impact of riveting process variables on the interference fit was delineated via contour map illustrations, and a thorough analysis of the interactive effects among these variables was conducted. Findings indicate that the interference in the riveted joint escalates dramatically with augmentations in the thickness of the composite plate. Conversely, the interference displays an initial increase followed by a decrease as the thickness of the metal plate is augmented, while exhibiting minimal sensitivity to variations in riveting displacement. The interactive effects between the composite plate thickness and riveting displacement, as well as metal plate thickness, exhibit a pronounced intensification with increasing composite plate thickness. Specifically, when the thickness of the composite plate is below 3&#xa0;mm, the interaction effect remains relatively stable, yet it intensifies considerably when the thickness exceeds 3&#xa0;mm. Regarding the metal plate thickness, the interaction with riveting displacement intensifies with increasing thickness up to 2.15&#xa0;mm, beyond which it exhibits a progressive decline.</p>