Insertion behavior study of multi-material self-piercing rivet joints by means of finite element simulation
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Fuel economy improvement
Over the last few years, fuel economy improvement has driven the use of efficient multi-material structures in the car industry. The combination of dissimilar materials, such as metal-metal and metal-polymer, is a complex issue that requires the use of different and emerging joining techniques. In this context, self-pierce riveting (SPR) is an extremely suitable technique for joining two or more metal sheets, particularly when other techniques are not applicable. SPR requires short manufacturing times and provides both high strength and high fatigue resistance. Yet, this technique still faces some hurdles, such as joining Ultra High Strength Steels (UHSS) with high strength low ductility aluminum alloys, which can result in rivet cracking or aluminum button tearing. Suitable process parameters, including the rivet size and the die profile, are usually obtained through a physical testing procedure to satisfy the required joint specification. This is both expensive and time consuming. ...