Testing and modelling of flow-drill screw connections under quasi-static loadings

The behaviour of a flow-drill screw connection under different quasi-static loadings was simulated using finite element models with detailed solid element meshes. The numerical models were developed with a rate-independent isotropic hypoelastic-plastic material model. A process-effect analysis was conducted, including investigation of the microstructure as well as hardness tests. Based on the investigation, the process effects were considered negligible. A simple approach for building up the geometry of the connection was presented. An experimental programme consisting of five different single-connector tests was carried out to characterise the connection, and was presented in detail. Each test was simulated, allowing for one-to-one comparisons between tests and simulations. Satisfactory results were achieved.