Numerical modeling of self-pierce riveting—From riveting process modeling down to structural analysis

Self-pierce riveting (SPR) is becoming increasingly used in the automotive industry as a way to join materials of different nature. In this paper we focus on the numerical modeling of the SPR process and to the final assembly mechanical strength. The simulation of such a joining process requires contact between deformable bodies, plastic deformation, damage and fracture. The Forge2005® finite element software enables to model large deformation of elastic–plastic materials for 2D and 3D configurations. A Lemaitre coupled damage model has been implemented to deal with damage during the process and fracture is modeled using the “kill element” technique. After a 2D simulation of the riveting process, it is possible to export the mechanical fields onto a 3D mesh and then to perform a 3D shearing test on the riveted structure. We can check the influence of the transfer of important mechanical fields, such as residual stresses or damage, on the final mechanical strength of the riveted specimen. The mechanical history of the rivet/sheet assembly undergone during the riveting process plays a significant role in the numerical prediction of the final strength of the assembly.