Simulation and Optimization of Self-pierce Riveting Process for 6061-T6 Aluminum Alloy

PENG Xin; ZHOU Ping; ZHAI Yanbo; WANG Nengjun

doi:10.3969/j.issn.1674-6457.2025.09.001

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (9) : 1-13. DOI: 10.3969/j.issn.1674-6457.2025.09.001

Light Alloy Forming

Simulation and Optimization of Self-pierce Riveting Process for 6061-T6 Aluminum Alloy

PENG Xin¹, ZHOU Ping^1,*, ZHAI Yanbo¹, WANG Nengjun²

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Abstract

The work aims to explore a method for selecting appropriate molds and rivets for engineering applications. A refined model of self-pierce riveting forming of 6061-T6 aluminum alloy with a thickness of 2 mm was established using ABAQUS software, and the influence of process parameters on the quality of joints was investigated based on this model. The material parameters of rivets with different hardness were obtained inversely by using the parameter identification method, and the accuracy of the refined model was verified through experiments; The influence of the flat-bottomed concave die size on the cross-sectional size and bottom morphology of the joints was investigated; and the influences of the length of rivets and the hardness of rivets on the quality of the joints were investigated based on the optimization of the concave die size. The results showed that the error of the joint cross-sectional size between test and simulation was controlled within 7%, and the established model could accurately simulate the forming process of self-pierce riveted joints; The bottom cut and leg tension were positively correlated with the depth of concave die, and the bottom thickness was negatively correlated with the depth of concave die, in which when the depth of the concave die was 1.6 mm, the cross-sectional size of the joint was the best and the bottom was free of cracks; it could be seen from the single-lap tensile shear and cross tensile tests that the riveted joint quality and bottom morphology were affected by the optimized concave die size, and the length of rivets and hardness of rivets was 6 mm. When the rivet length was 6 mm and the hardness was H4, the quality of the joint was the best, and its tensile shear and tensile forces were 8.3 kN and 4.3 kN, respectively, and the corresponding failure displacements were 4.3 mm and 8.9 mm. The proposed method based on the combination of finite-element simulation and experimental validation overcomes the problems of the empirical method of long time-consuming and high cost, and is able to accurately and efficiently select the optimal mold-rivet combinations with high engineering practicality.

Key words

6061-T6 aluminum alloy / self-pierce riveting simulation / parameter identification / riveting die and rivet selection / evaluation of connector quality / mechanical performance test

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PENG Xin, ZHOU Ping, ZHAI Yanbo, WANG Nengjun. Simulation and Optimization of Self-pierce Riveting Process for 6061-T6 Aluminum Alloy[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 1-13 https://doi.org/10.3969/j.issn.1674-6457.2025.09.001

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Funding

Special Funds for Basic Research Operating Costs of Central Universities (SWU7130200010/076); National Natural Science Foundation of China (51975479, 52174374)