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

Abstract

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

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.

Figures/Tables 21

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

References 26

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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

Research on the Forming Quality and Mechanical Properties of Flat-Surface-Overlapped Self-piercing Riveted Aluminum Alloy Joints

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