Realtime Prediction of Self-Pierce Riveting Joints - Prognosis and Visualization Based on Simulation and Machine Learning

Machine learning is used in many fields nowadays to predict events, be it a pure classification or the prediction of certain values. Thus, these methods are also increasingly used in mechanical joining technology, for example for the prediction of joint strengths, in the classification of defects and rivet head positions or in the prediction of discrete result values such as interlock. This paper further shows how the complete joint contour including the output of stresses, strains and damage can be predicted and visualized in real time for self-piercing riveting with semi-tubular rivet. First, classical sampling is carried out in experiments with steel and aluminum sheets of different types and thicknesses. These are used as a basis for the qualification of the numerical simulations. For this validation experiments and simulations are compared via joint contour and force curves. For the simulations validated in such way several tool variants are carried out in variation calculations for each material-thickness combination. The simulation meshes of the thus generated database are standardized with respect to comparability (same number of nodes) and a data reduction is performed. After testing different approximation approaches, the best possible results are predicted and can be visualized in the developed software demonstrator.