The numerical analysis of the effect of the joining process parameters on self-piercing riveting using the solid rivet

This paper presents the numerical modeling of the self-piercing riveting using the solid rivet. The joint forming capabilities were presented using the FEM analysis, on the example of two steel sheets made of DC01, and on the example where the upper sheet was made of DC01 and the lower sheet was made of EN AW-AlMg3 aluminum alloy. The numerical analysis of the joint forming was performed using sheets of identical thickness of 1.5 mm and at conventional tool movements.The effect of the layout change and the number of grooves in the universal rivet on the stress distribution were determined.In this paper, the groove filling with the joined sheet material depending on selected factors of the joining process was also compared. The capabilities of joining with a different tool movement solution were presented. The correctness of the numerical model was validated based on metallographic researches and the force characteristics of the process.