Finite Element Simulation of the Self-Piercing Riveting Process

This work is focused on the development of a numerical model with the help of the finite element method to predict the magnitude and distribution of deformation associated with the self-piercing riveting process. A 2D axisymmetric model of the self-piercing riveting process is presented using the commercial implicit finite element code MSC.Superform. The flow stress of the work-material is taken as a function of strain, strain-rate and temperature. The shape of the rivet joint and the stress, strain and damage in both of the rivet and workpiece sheets are determined. The information obtained from the process simulation, such as force, metal flow and details of die fill are discussed. The calculated punching forces and the shape of the rivet joint are compared with experimental data and found to be in good agreement. Defects in the riveting are analyzed and are categorized into penetration, necking and lap formation. The effects of workpiece temperature on punching force were also discussed.