Conventional fusion joining methods, such as resistance spot welding (RSW), have been demonstrated to be ineffective for magnesium alloys. However, self-pierce riveting (SPR) has recently been shown as an attractive joining technique for lightweight metals, including magnesium alloys. While the SPR joining process has been experimentally established on magnesium alloys through trial and error, this joining process is not fully developed. As such, in this work, we explore simulation techniques for modeling the SPR process that could be used to optimize this joining method for magnesium alloys. Due to the process conditions needed to rivet the magnesium sheets, high strain rates and adiabatic heat generation are developed that require a robust material model. Thus, we employ an internal state variable (ISV) plasticity material model that captures strain-rate and temperature dependent deformation. In addition, we explore various damage modeling techniques needed to capture the piercing process observed in the joining of magnesium alloys. The simulations were performed using a two-dimensional axisymmetric model with various element deletion criterions resulting in good agreement with experimental data. The simulations results of this study show that the ISV material model is ideally suited for capturing the complex physics of the plasticity and damage observed in the SPR of magnesium alloys.
Issue Section:
Research Papers
Topics:
Damage,
Deformation,
Finite element analysis,
Magnesium alloys,
Riveting,
Rivets,
Simulation,
Temperature,
Stress,
Plasticity,
Heat,
Failure,
Modeling
References
1.
Atzeni
, E.
, Ippolito
, R.
, and Settineri
, L.
, 2009
, “Experimental and Numerical Appraisal of Self-Piercing Riveting
,” CIRP Ann. Manuf. Technol.
, 58
(1
), pp. 17
–20
.10.1016/j.cirp.2009.03.0812.
Barnes
, T. A.
, and Pashby
, I. R.
, 2000
, “Joining Techniques for Aluminum Spaceframes Used in Automobiles Part II—Adhesive Bonding and Mechanical Fasteners
,” J. Mater. Process. Technol.
, 99
(1–3
), pp. 72
–79
.10.1016/S0924-0136(99)00361-13.
Yan
, J.
, Xu
, Z.
, and Li
, Z.
, 2005
, “Microstructure Characteristics and Performance of Dissimilar Welds Between Magnesium Alloy and Aluminum Formed by Friction Stirring
,” Scr. Mater.
, 53
(5
), pp. 585
–589
.10.1016/j.scriptamat.2005.04.0224.
Czerwinski
, F.
, 2011
, “Welding and Joining of Magnesium Alloys
,” Magnesium Alloys—Design, Processing and Properties
, F.
Czerwinski
, ed., Intech
, Bolton, ON, Canada
, pp. 469
–491
.5.
Florea
, R. S.
, Solanki
, K. N.
, Bammann
, D. J.
, Baird
, J. C.
, Jordon
, J. B.
, and Castanier
, M. P.
, 2012
, “Resistance Spot Welding of 6061-T6 Aluminum: Failure Loads and Deformation
,” Mater. Des.
, 34
(1–4
), pp. 624
–630
.10.1016/j.matdes.2011.05.0176.
Ren
, D.
, Liu
, L.
, and Li
, Y.
, 2011
, “Investigation on Overlap Joining of AZ61 Magnesium Alloy: Laser Welding, Adhesive Bonding, and Laser Weld Bonding
,” Int. J. Adv. Manuf. Technol.
, 61
(1–4
), pp. 195
–204
.10.1007/s00170-011-3683-x7.
Harooni
, M.
, Carlson
, B.
, and Kovacevic
, R.
, 2014
, “Dual-Beam Laser Welding of AZ31B Magnesium Alloy in Zero-Gap Lap Joint Configuration
,” Opt. Laser Technol.
, 56
(1
), pp. 247
–255
.10.1016/j.optlastec.2013.08.0188.
Jordon
, J. B.
, Horstemeyer
, M. F.
, Daniewicz
, S. R.
, Badarinarayan
, H.
, and Grantham
, J.
, 2010
, “Fatigue Characterization and Modeling of Friction Stir Spot Welds in Magnesium AZ31 Alloy
,” ASME J. Eng. Mater. Technol.
, 132
(4
), p. 41008
.10.1115/1.40023309.
Wang
, J. W.
, Liu
, Z. X.
, Shang
, Y.
, Liu
, A. L.
, Wang
, M. X.
, Sun
, R. N.
, and Wang
, P.-C.
, 2011
, “Self-Piercing Riveting of Wrought Magnesium AZ31 Sheets
,” ASME J. Manuf. Sci. Eng.
, 133
(3
), p. 031009
.10.1115/1.400413810.
Porcaro
, R.
, Hanssen
, A. G.
, Langseth
, M.
, and Aalberg
, A.
, 2006
, “Self-Piercing Riveting Process: An Experimental and Numerical Investigation
,” J. Mater. Process. Technol.
, 171
(1
), pp. 10
–20
.10.1016/j.jmatprotec.2005.05.04811.
He
, X.
, Pearson
, I.
, and Young
, K.
, 2008
, “Self-Pierce Riveting for Sheet Materials: State of the Art
,” J. Mater. Process. Technol.
, 199
(1–3
), pp. 27
–36
.10.1016/j.jmatprotec.2007.10.07112.
Durandet
, Y.
, Deam
, R.
, Beer
, A.
, Song
, W.
, and Blacket
, S.
, 2010
, “Laser Assisted Self-Pierce Riveting of AZ31 Magnesium Alloy Strips
,” Mater. Des.
, 31
(1
), pp. S13
–S16
.10.1016/j.matdes.2009.10.03813.
Casalino
, G.
, Rotondo
, A.
, and Ludovico
, A.
, 2008
, “On the Numerical Modelling of the Multiphysics Self Piercing Riveting Process Based on the Finite Element Technique
,” Adv. Eng. Softw.
, 39
(9
), pp. 787
–795
.10.1016/j.advengsoft.2007.12.00214.
Hoang
, N.-H.
, Porcaro
, R.
, Langseth
, M.
, and Hanssen
, A.-G.
, 2010
, “Self-Piercing Riveting Connections Using Aluminium Rivets
,” Int. J. Solids Struct.
, 47
(3–4
), pp. 427
–439
.10.1016/j.ijsolstr.2009.10.00915.
Huang
, L.
, Lasecki
, J. V.
, Guo
, H.
, and Su
, X.
, 2014
, “Finite Element Modeling of Dissimilar Metal Self-Piercing Riveting Process
,” SAE Int. J. Mater. Manf.
, 7
(3
), pp. 698
–705
.10.4271/2014-01-198216.
Bouchard
, P. O.
, Laurent
, T.
, and Tollier
, L.
, 2008
, “Numerical Modeling of Self-Pierce Riveting—From Riveting Process Modeling Down to Structural Analysis
,” J. Mater. Process. Technol.
, 202
(1–3
), pp. 290
–300
.10.1016/j.jmatprotec.2007.08.07717.
Bammann
, D.
, 1984
, “An Internal Variable Model of Viscoplasticity
,” Int. J. Eng. Sci.
, 22
(8
), pp. 1041
–1053
.10.1016/0020-7225(84)90105-818.
Bammann
, D.
, and Aifantis
, E. C.
, 1989
, “A Damage Model for Ductile Metals
,” Nucl. Eng. Des.
, 116
(3
), pp. 355
–362
.10.1016/0029-5493(89)90095-219.
Bammann
, D. J.
, Chiesa
, M. L.
, and Johnson
, G. C.
, 1996
, “Modeling Large Deformation and Failure in Manufacturing Processes
,” Theoretical and Applied Mechanics
, T.
Tatsumi
, E.
Wannabe
, and T.
Kambe
, eds., Elsevier
, Amsterdam, The Netherlands
, pp. 256
–276
.20.
Horstemeyer
, M.
, and Gokhale
, A.
, 1999
, “A Void–Crack Nucleation Model for Ductile Metals
,” Int. J. Solids Struct.
, 36
(33
), pp. 5029
–5055
.10.1016/S0020-7683(98)00239-X21.
Marin
, E. B.
, Bammann
, D. J.
, Regueiro
, R. A.
, and Johnson
, G. C.
, 2006
, “On the Formulation, Parameter Identification and Numerical Integration of the EMMI Model: Plasticity and Isotropic Damage
,” Sandia National Laboratories, Livermore, CA, Report No. SAND2006-0200.22.
Horstemeyer
, M. F.
, 2001
, “From Atoms to Autos: A New Design Paradigm Using Microstructure-Property Modeling. Part 1: Monotonic Loading Conditions
,” Sandia National Laboratories, Livermore, CA, Report No. SAND2000-8662.23.
Horstemeyer
, M. F.
, and Wang
, P.
, 2004
, “Cradle-to-Grave Simulation-Based Design Incorporating Multiscale Microstructure-Property Modeling: Reinvigorating Design With Science
,” J. Comput. Mater. Des.
, 10
(1
), pp. 13
–34
.10.1023/B:JCAD.0000024171.13480.2424.
Jordon
, J. B.
, Horstemeyer
, M. F.
, Solanki
, K.
, and Xue
, Y.
, 2007
, “Damage and Stress State Influence on the Bauschinger Effect in Aluminum Alloys
,” Mech. Mater.
, 39
(10
), pp. 920
–931
.10.1016/j.mechmat.2007.03.00425.
Cocks
, A. C. F.
, and Ashby
, M. F.
, 1980
, “Intergranular Fracture During Power-Law Creep Under Multiaxial Stresses
,” Met. Sci.
, 14
(8–9
), pp. 8
–9
.10.1179/03063458079044118726.
Cocks
, A. C. F.
, and Ashby
, M. F.
, 1982
, “On Creep Fracture By Void Growth
,” Prog. Mater. Sci.
, 27
(3–4
), pp. 189
–244
.10.1016/0079-6425(82)90001-927.
Hasenpouth
, D.
, 2010
, “Tensile High Strain Rate Behavior of AZ31B Magnesium Alloy Sheet
,” Master thesis, University of Waterloo, Waterloo, ON, Canada.28.
Wu
, H.
, Sun
, P.
, and Lin
, F.
, 2011
, “Anisotropic and Tensile Flow Behaviors of Mg Alloy AZ31B Thin Sheet in H24 Condition at Elevated Temperatures
,” Mater. Sci. Eng. A
, 528
(6
), pp. 2522
–2531
.10.1016/j.msea.2010.11.08229.
LSTC
, 2012
, LS-DYNA Keyword User's Manual, Livermore Software Technology Corp., Livermore, CA.30.
Bammann
, D.
, Chiesa
, M.
, Horstemeyer
, M. F.
, and Weingarten
, L.
, 1993
, “Failure in Ductile Material Using Finite Element Methods
,” Structural Crashworthiness and Failure
, N.
Jones
, and T.
Weirzbicki
, eds., Elsevier Applied Science
, London, UK
, pp. 1
–52
.31.
Ceretti
, E.
, Fiorentino
, A.
, and Giardini
, C.
, 2008
, “Process Parameters Influence on Friction Coefficient in Sheet Forming Operations
,” Int. J. Mater. Form.
, 1
(S1
), pp. 1219
–1222
.10.1007/s12289-008-0161-632.
Bolz
, R. E.
, and Tuve
, G. L.
, 1973
, CRC Handbook of Tables for Applied Engineering Science
, CRC Press
, Boca Raton, FL
.33.
Xu
, W. L.
, Ma
, C. H.
, Li
, C. H.
, and Feng
, W. J.
, 2004
, “Sensitive Factors in Springback Simulation for Sheet Metal Forming
,” J. Mater. Process. Technol.
, 151
(1–3
), pp. 217
–222
.10.1016/j.jmatprotec.2004.04.04434.
Finn
, M. J.
, Galbraith
, P. C.
, Wu
, L.
, Hallquist
, J. O.
, Lum
, L.
, and Lin
, T.-L.
, 1995
, “Use of a Coupled Explicit-Implicit Solver for Calculating Spring-Back in Automotive Body Panels
,” J. Mater. Process. Technol.
, 50
(1–4
), pp. 395
–409
.10.1016/0924-0136(94)01401-L35.
Aberlenc
, F.
, and Babeau
, J.-L.
, 1992
, “OPTRIS and FICTURE: Industrial Tools to Modelize Sheet Metal Forming
,” J. Mater. Process. Technol.
, 34
(1–4
), pp. 125
–132
.10.1016/0924-0136(92)90098-D36.
Ahad
, F. R.
, Enakoutsa
, K.
, Solanki
, K. N.
, and Bammann
, D. J.
, 2014
, “Nonlocal Modeling in High-Velocity Impact Failure of 6061-T6 Aluminum
,” Int. J. Plast.
, 55
, pp. 108-132.10.1016/j.ijplas.2013.10.001Copyright © 2015 by ASME
You do not currently have access to this content.
