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<p>The riveting process for copper busbars is investigated and optimized in this study using a three-dimensional smooth particle Galerkin (SPG) and finite element (FE) analysis. The SPG–FE method is employed to establish a simulation model, which is then validated through experimental testing. Key design parameters, such as busbar thickness, pre-drilled hole diameter, rivet nut shank length, rivet nut tooth height, and anti-pull-out groove inclination angle, are systematically investigated for their impact on riveting quality. The riveting process entails pressing the rivet nut into the busbar’s pre-drilled hole, causing the material to plastically deform and cold flow into the anti-pull-out groove. Response surface methodology (RSM) is used to predict the relationship between pull-out force and the investigated parameters, which is then maximized using the NLPQLP optimization method. The results show that busbar thickness and pre-drilled hole diameter are the most sensitive to changes in pull-out force, with the maximum pull-out force associated with a busbar thickness of 2.38 mm. The established simulation-based framework, combined with predictive models and optimization techniques, provides engineers with a powerful tool for developing improved riveting solutions for busbars in power distribution units (PDUs) for e-mobility.</p>

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Optimization of riveting quality in copper busbars for e-mobility using smooth particle Galerkin and finite element method

  • 期刊论文

  • 发表日期：

    2025年11月25日

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  • Jianhui Zhang,
  • Yaopeng Hu,
  • Xuan Qin,
  • Xianchao Yan,
  • Amir Najibi

摘要

The riveting process for copper busbars is investigated and optimized in this study using a three-dimensional smooth particle Galerkin (SPG) and finite element (FE) analysis. The SPG–FE method is employed to establish a simulation model, which is then validated through experimental testing. Key design parameters, such as busbar thickness, pre-drilled hole diameter, rivet nut shank length, rivet nut tooth height, and anti-pull-out groove inclination angle, are systematically investigated for their impact on riveting quality. The riveting process entails pressing the rivet nut into the busbar’s pre-drilled hole, causing the material to plastically deform and cold flow into the anti-pull-out groove. Response surface methodology (RSM) is used to predict the relationship between pull-out force and the investigated parameters, which is then maximized using the NLPQLP optimization method. The results show that busbar thickness and pre-drilled hole diameter are the most sensitive to changes in pull-out force, with the maximum pull-out force associated with a busbar thickness of 2.38 mm. The established simulation-based framework, combined with predictive models and optimization techniques, provides engineers with a powerful tool for developing improved riveting solutions for busbars in power distribution units (PDUs) for e-mobility.