平面搭接自冲铆接铝合金接头的成形质量和力学性能研究

doi:10.19562/j.chinasae.qcgc.2025.08.013

摘要/Abstract

摘要：

为提升自冲铆接在连接厚铝合金板时的接头质量，提出了平面搭接自冲铆接（flat-surface-overlapped self-piercing riveting， FS-SPR）工艺。制作了5种接头用于研究铆接距离、搭接距离和搭接面类型的影响。通过准静态和疲劳试验研究了FS-SPR接头准静态和疲劳载荷下的力学性能和失效行为。通过有限元仿真研究了FS-SPR工艺的成形机理，并探讨了工艺参数对斜面搭接的FS-SPR接头成形质量的影响。结果表明J1、J3、J4接头可形成良好机械互锁，而J2接头因下层板厚度不足未能形成机械互锁，J5接头因组合厚度大而出现铆钉弯曲。仿真结果表明，搭接长度须超过40 mm，铆接位置宜中间偏右，板材厚度和铆钉长度须优化以提升成形质量。合理设计的J1和J3接头优于传统搭接的J5接头。J5接头峰值力和能量吸收分别比J1接头低1.7%和28.6%，比J3接头低10.7%和6.4%。当载荷水平相同时，J3接头的疲劳寿命平均比J5接头高70%。

关键词: 铝合金, 平面搭接自冲铆接, 成形质量, 力学性能, 有限元仿真

Abstract:

A flat-surface-overlapped self-piercing riveting （FS-SPR） process is proposed to improve the joint quality in joining thick aluminum alloy sheets using self-piercing riveting （SPR）. Firstly， five different joints are fabricated to study the effect of riveting distance， overlap distance， and overlap surface type. Secondly， the mechanical properties and failure behavior under quasi-static and fatigue loads of FS-SPR joints are investigated through quasi-static and fatigue tests. Finite element simulation is conducted to study the forming mechanism of the FS-SPR process and explore the influence of process parameters on the forming quality of the FS-SPR joints with an inclined overlap surface. The results show that J1， J3， and J4 joints can form good mechanical interlock， while joint J2 fails to form mechanical interlock due to inadequate lower sheet thickness， and J5 joint experiences rivet bending due to large stack thickness. The simulation result shows that the overlap length needs to exceed 40 mm， the riveting position should be to the right of the middle， and the optimization of sheet thickness and rivet length is necessary to improve forming quality. Well-designed J1 and J3 joints outperform the traditional overlapped J5 joint. The peak force and energy absorption of J5 joint are 1.7% and 28.6% lower than J1 joint， and 10.7% and 6.4% lower than J3 joint， respectively. When subjected to the same load level， the fatigue life of J3 joint is on average 70% higher than that of J5 joint.

Key words: aluminum, FS-SPR, forming quality, mechanical properties, finite element simulation

王超,于万元,成艾国,何智成,陈涛. 平面搭接自冲铆接铝合金接头的成形质量和力学性能研究[J]. 汽车工程, 2025, 47(8): 1573-1587.

Chao Wang,Wanyuan Yu,Aiguo Cheng,Zhicheng He,Tao Chen. Research on the Forming Quality and Mechanical Properties of Flat-Surface-Overlapped Self-piercing Riveted Aluminum Alloy Joints[J]. Automotive Engineering, 2025, 47(8): 1573-1587.

图/表 21

图1

图2

图3

表1

材料属性"

材料

弹性模量E/GPa

密度ρ/

（kg·m^-3）

泊松比

ν

屈服σ_y_/

MPa

6063-T6

2.70×10³

0.3

244

铆钉

210

7.83×10³

0.3

1 340

表1

图4

图5

表2

图6

图7

图8

图9

图10

图11

表3

图12

图13

图14

图15

图16

图17

图18

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接头参数	J1	J2	J3	J4	J5
上层板厚度 T_t/mm	3.0	3.0	3.0	1.5	3.0
下层板厚度 T_b/mm	3.0	3.0	3.0	1.5	3.0
接头类型	I	I	II	III	III
铆接距离 L_r/mm	20.0	15.0	20.0	20.0	20.0
搭接距离 L_l/mm	40.0	30.0	40.0	40.0	40.0
铆钉和模具组合	RD-II	RD-II	RD-II	RD-II	RD-I


研究对象	L_l/mm	L_r/mm	T_s/mm	R_l/mm	研究对象	L_l/mm	L_r/mm	T_s/mm	R_l/mm
搭接长度	20.0	10.0	3.0	5.0	板材厚度	40.0	20.0	2.0	5.0
	25.0	12.5	3.0	5.0		40.0	20.0	2.5	5.0
	30.0	15.0	3.0	5.0		40.0	20.0	3.0	5.0
	35.0	17.5	3.0	5.0		40.0	20.0	3.5	5.0
	40.0	20.0	3.0	5.0		40.0	20.0	4.0	5.0
	45.0	22.5	3.0	5.0		40.0	20.0	4.5	5.0
	50.0	25.0	3.0	5.0		40.0	20.0	5.0	5.0
铆接位置	40.0	10.0	3.0	5.0		40.0	20.0	5.5	5.0
	40.0	15.0	3.0	5.0		40.0	20.0	6.0	5.0
	40.0	20.0	3.0	5.0	铆钉长度	40.0	20.0	3.0	4.0
	40.0	25.0	3.0	5.0		40.0	20.0	3.0	4.5
	40.0	30.0	3.0	5.0		40.0	20.0	3.0	5.5
	40.0	35.0	3.0	5.0		40.0	20.0	3.0	6.0