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Development of a New Self-flaring Rivet Geometry Using Finite Element Method and Design of Experiments

: Kraus, Christian; Falk, Tobias; Mauermann, Reinhard; Drossel, Welf-Guntram

Volltext ()

Procedia manufacturing 47 (2020), S.383-388
ISSN: 2351-9789
International Conference on Material Forming (ESAFORM) <23, 2020, Online>
Zeitschriftenaufsatz, Konferenzbeitrag, Elektronische Publikation
Fraunhofer IWU ()
mechanical joining; finite element method; design of experiments

The paper presents a new joining process for mixed joints of metallic and non-metallic materials. The process bases on a self-flaring rivet, which lances the joining partners and, due to its geometry, produces an interlock. In contrast to conventional self-piercing processes such as self-pierce riveting with semi-tubular rivets (SPR), the new process does not require a special shaped die as counter tool. The development of the rivet geometry is carried out with the aid of FEM analyses in SFTC Deform-3D. Design of experiments (DoE) is used to find a suitable rivet geometry that is stable enough to lance high-strength steel. However, the rivet element must be flaring to produce an interlock. The challenges and solution approaches associated with the modelling of material damage and separation in the three-dimensional calculation models of the riveting process are presented. The consideration of macromechanical and geometrical criteria for element deletion is important in order to obtain robust models with useful results. The validation of the model is done by comparing the simulation results with experimental data.