Determining the influence of different process parameters on the versatile self-piercing riveting process using numerical methods

Owing to the increasing use of multi-material construction and the resulting material incompatibilities, mechanical joining technologies are gaining importance. The reasons for this are the variety of joining possibilities as well as the high joint load-bearing capacities. However, the currently rigid tool systems cannot react flexibly to changing process conditions, such as varying sheet thicknesses or strengths as they require a change in the tool configuration. Therefore, a novel, versatile self-piercing riveting process (V-SPR) is proposed to improve the applicability of joining several sheet material combinations by considering only one rivet-die combination. Although previous studies have demonstrated the potential of V-SPR for joining equal materials, the present understanding of the process lacks detailed investigations regarding optimal tool configurations and sheet-joining tasks, such as varying the total and individual blank thicknesses. In this regard, a systematic parameter study in combination with statistical analyses is conducted to determine the applicability and feasibility of V-SPR using EN AW-6014 as an example. The process recommendations and limitations discussed in this paper pave the way for meaningful use of novel rivet geometry in versatile process chains.