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Process modeling, joint-property characterization and construction of joint connectors for mechanical fastening by self-piercing riveting

Mica Grujicic (Department of Mechanical Engineering, Clemson University, Clemson, South Carolina, USA)
Jennifer Snipes (Department of Mechanical Engineering, Clemson University, Clemson, South Carolina, USA)
S. Ramaswami (Department of Mechanical Engineering, Clemson University, Clemson, South Carolina, USA)
Fadi Abu-Farha (Department of Automotive Engineering, Clemson University, Clemson, South Carolina, USA)

Multidiscipline Modeling in Materials and Structures

ISSN: 1573-6105

Article publication date: 4 November 2014

Abstract

Purpose

The purpose of this paper is to propose a computational approach in order to help establish the effect of various self-piercing rivet (SPR) process and material parameters on the quality and the mechanical performance of the resulting SPR joints.

Design/methodology/approach

Toward that end, a sequence of three distinct computational analyses is developed. These analyses include: (a) finite-element modeling and simulations of the SPR process; (b) determination of the mechanical properties of the resulting SPR joints through the use of three-dimensional, continuum finite-element-based numerical simulations of various mechanical tests performed on the SPR joints; and (c) determination, parameterization and validation of the constitutive relations for the simplified SPR connectors, using the results obtained in (b) and the available experimental results. The availability of such connectors is mandatory in large-scale computational analyses of whole-vehicle crash or even in simulations of vehicle component manufacturing, e.g. car-body electro-coat paint-baking process. In such simulations, explicit three-dimensional representation of all SPR joints is associated with a prohibitive computational cost.

Findings

It is found that the approach developed in the present work can be used, within an engineering optimization procedure, to adjust the SPR process and material parameters (design variables) in order to obtain a desired combination of the SPR-joint mechanical properties (objective function).

Originality/value

To the authors’ knowledge, the present work is the first public-domain report of the comprehensive modeling and simulations including: self-piercing process; virtual mechanical testing of the SPR joints; and derivation of the constitutive relations for the SPR connector elements.

Keywords

Citation

Grujicic, M., Snipes, J., Ramaswami, S. and Abu-Farha, F. (2014), "Process modeling, joint-property characterization and construction of joint connectors for mechanical fastening by self-piercing riveting", Multidiscipline Modeling in Materials and Structures, Vol. 10 No. 4, pp. 631-658. https://doi.org/10.1108/MMMS-04-2014-0024

Publisher

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Emerald Group Publishing Limited

Copyright © 2014, Emerald Group Publishing Limited