Numerical Study on Die Design Parameters of Self-Pierce Riveting Process Based on Orthogonal Test

doi:10.1007/s12204-014-1504-8

Abstract

Abstract: The concave die design of self-pierce riveting (SPR) is of critical importance for product quality. The optimization of concave die parameters based on orthogonal test is proposed to explore the relationship between self-pierce riveted joint quality and die parameters. There are nine independent die parameter factors in orthogonal test and each factor has 4 levels. In order to evaluate the interlock and neck thickness, we carry out numerical simulations by the software DEFORM-2D. Then, the primary and secondary factors that affect the joint quality have been found out by means of range analysis. Finally, an optimization scheme is brought forward to design concave die in SPR process, which indicates that the joint has higher quality than that of former orthogonal tests. This work can be extended by a detailed mechanical and fatigue analysis for the joint quality of SPR process.

Key words: self-pierce riveting (SPR)| orthogonal test| concave die| joint

摘要： The concave die design of self-pierce riveting (SPR) is of critical importance for product quality. The optimization of concave die parameters based on orthogonal test is proposed to explore the relationship between self-pierce riveted joint quality and die parameters. There are nine independent die parameter factors in orthogonal test and each factor has 4 levels. In order to evaluate the interlock and neck thickness, we carry out numerical simulations by the software DEFORM-2D. Then, the primary and secondary factors that affect the joint quality have been found out by means of range analysis. Finally, an optimization scheme is brought forward to design concave die in SPR process, which indicates that the joint has higher quality than that of former orthogonal tests. This work can be extended by a detailed mechanical and fatigue analysis for the joint quality of SPR process.

关键词: self-pierce riveting (SPR)| orthogonal test| concave die| joint

CLC Number:

TG 386.1

HAN Shan-ling* (韩善灵), LI Zhi-yong (李志勇), GAO Yuan (高远), ZENG Qing-liang (曾庆良). Numerical Study on Die Design Parameters of Self-Pierce Riveting Process Based on Orthogonal Test[J]. Journal of shanghai Jiaotong University (Science), 2014, 19(3): 308-312.

References

[1] He X C, Gu F S, Ball A. Recent development in finite element analysis of self-piercing riveted joints [J]. International Journal of Advanced Manufacturing Technology, 2012, 58(5-8): 643-649.
[2] Miyashita Y, Teow Y C J, Karasawa T, et al.Strength of adhesive aided SPR joint for AM50 magnesium alloy sheets [J]. Procedia Engineering, 2011, 10:2532-2537.
[3] Xu Y. Effects of factors on physical attributes of selfpiercing riveted joints [J]. Science and Technology of Welding & Joining, 2006, 11(6): 666-671.
[4] Hoang N H, Porcaro R, Langseth M, et al. Selfpiercing riveting connections using aluminium rivets[J]. International Journal of Solids and Structures,2010, 47(3-4): 427-439.
[5] Mucha J. A study of quality parameters and behaviour of self-piercing riveted aluminium sheets with different joining conditions [J]. Journal of Mechinal Engineering, 2011, 57(4): 323-333.
[6] Lou Ming, Li Yong-bing, Huang Shu-yan, et al. Influence of die-rivet volume ratio on forming performance of self-piercing riveting joints of dissimilar materials[J]. China Mechanical Engineering, 2009, 20(15):1873-1876 (in Chinese).
[7] Jin Xin, Li Yong-bing, Lou Ming, et al. Process optimization of self-piercing riveting aluminum to high strength steel using DOE method [J]. Chinese Journal of Automotive Engineering, 2011, 1(3): 185-191(in Chinese).
[8] Abe Y, Kato T, MoriK. Joinability of aluminium alloy and mild steel sheets by self piercing rivet [J]. Journal of Materials Processing Technology, 2006, 177(1-3): 417-421.
[9] Fu Z M, Mo J H, Zhang W X. Study on multiplestep incremental air-bending forming of sheet metal with springback model and FEM simulation [J].The International Journal of Advanced Manufacturing Technology, 2009, 45(5): 448-458.
[10] Hu Zhi-yin, Meng Guang-yao, Xia Hai-tao. Research on surface roughness of high speed milling GH4169 based on orthogonal test method [J]. Manufacturing Technology & Machine Tool, 2011(1): 44-46 (in Chinese)

[1]	MA Yongliang, CHEN Wei, HAN Chaoshuai, ZHANG Yingming, CHEN Xiaokang. Joint Distribution of Short-Term Waves Height and Period Based on Wallops Spectrum [J]. Journal of Shanghai Jiao Tong University, 2026, 60(3): 377-386.
[2]	Xiao Lei, Zhao Hailong, Wu Xun, Wang Jun, Zhou Qihong. Hybrid Learning Model for Cross-Device Fault Detection of Industrial Robot Joints [J]. J Shanghai Jiaotong Univ Sci, 2026, 31(1): 82-98.
[3]	HUO Fali, YANG Jichuan, ZHU Chenyang, WEI Changdong, ZHAO Yinzhi. Hydrodynamic Characteristics of Hybrid Mooring System with Dual-Platform Joint Operation [J]. J Shanghai Jiaotong Univ Sci, 2025, 30(6): 1242-1254.
[4]	YE Qichang, WAN Shizheng, LI Yueshu, CHEN Zhumei, LIU Shanglin. Research on Multi-Agent Training for Maritime Joint Air Defence Based on a Multi-Algorithm Framework with Adaptive Hierarchical Sharing [J]. Air & Space Defense, 2025, 8(6): 121-128.
[5]	CAO Huan, CAI Ao, CHEN Yangyu, ZUO Wenkang, CHEN Mantai. Behavior of High Strength Steel Butt Joints at Arctic Low Temperatures [J]. Journal of Shanghai Jiao Tong University, 2025, 59(4): 533-540.
[6]	CHENG Mingyang, XING Haijun, MI Yang, ZHANG Shenxi, TIAN Shuxin, SHEN Jie. Two-Stage Market Joint Clearance Considering Participation of Wind/Photovoltaic/Energy Storage Power Station in Flexible Ramping [J]. Journal of Shanghai Jiao Tong University, 2025, 59(10): 1451-1463.
[7]	HE Guisong (贺贵松), HUANG Xuegong^* (黄学功),LI Feng（李峰). Coordination Design of a Power-Assisted Ankle Exoskeleton Robot Based on Active-Passive Combined Drive [J]. J Shanghai Jiaotong Univ Sci, 2025, 30(1): 197-208.
[8]	WANG Zhi¹ (王智), OUYANG Yiping¹ (欧阳义平), YANG Qi^{1, 2∗} (杨启). Numerical Simulation on Effect of Indenter Radius During Point Load Test [J]. J Shanghai Jiaotong Univ Sci, 2024, 29(5): 909-918.
[9]	WANG Jinxiao¹ (王进潇), CHENG Bin^{1, 2, 3∗} (程斌), XIANG Sheng¹ (向升), LI Sida¹ (李思达), YAN Xingfei⁴ (闫兴非). Static and Fatigue Behavior of Hybrid Bonded/Bolted Glass Fiber Reinforced Polymer Joints Under Tensile Loading [J]. J Shanghai Jiaotong Univ Sci, 2024, 29(5): 817-830.
[10]	ZANG Hongyan, XIE Xiaolong, XU Yazhou, TAO Ye, GAO Changsheng. Hypersonic Maneuvering Target State Estimation Algorithm Based on Recurrent Neural Network [J]. Air & Space Defense, 2024, 7(4): 88-98.
[11]	WANG Xianfeng, ZOU Fan, LIU Chang, AN Qinglong, CHEN Ming. Influence of Countersink Fillet Radius on Mechanical Performance of CFRP/Al Bolted Joints [J]. Journal of Shanghai Jiao Tong University, 2024, 58(3): 342-351.
[12]	LIU Bingwen, WU Xiong, CAO Binrui, MA Song, HE Wenwen. Joint Planning of Regional Integrated Energy System Based on Enhanced Benders Decomposition [J]. Journal of Shanghai Jiao Tong University, 2024, 58(10): 1513-1523.
[13]	ZHANG Xiaoyu, ZHOU Yiliang, FENG Chong, YAO Lili. Application Status of Joining Technology for Composites in the Ship Field [J]. Ocean Engineering Equipment and Technology, 2024, 11(1): 145-150.
[14]	DONG Xin, XU Qun, SHAO Yunliang. Development of Mooring Connectors and its Application in Floating Offshore Wind Turbine [J]. Ocean Engineering Equipment and Technology, 2024, 11(1): 130-138.
[15]	ZHANG Xiangyue, ZHAO Baoxiang, CHEN Li, LIU Xianyu, YI Difei, FENG Meng, CHEN Tushun, ZHANG Quan. Study on Influences of Tubular Joint Flexibility Theory on Offshore Jacket Platform Global Strength Analysis [J]. Ocean Engineering Equipment and Technology, 2024, 11(1): 30-36.