Journal of Jilin University(Engineering and Technology Edition) ›› 2019, Vol. 49 ›› Issue (6): 1826-1835.doi: 10.13229/j.cnki.jdxbgxb20181075

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Simulation on peeling failure of self⁃piercing riveted joints insteel and aluminum alloy dissimilar sheets

Wei-min ZHUANG(),Yang LIU,Peng-yue WANG,Hong-da SHI,Ji-shuan XU   

  1. State Key Laboratory of Automotive Simulation and Control, Jilin University, Changchun 130022，China
  • Received:2018-10-12 Online:2019-11-01 Published:2019-11-08

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Abstract:

In order to study the peeling failure behavior of steel-aluminum self-piercing riveted (SPR) joints, peeling tests and simulation studies were carried out on two kinds of dissimilar SPR joints in 5754 aluminum alloy and Q235 steel sheets. The finite element model of T-type SPR joint was established based on the modified Mohr-Coulomb (MMC) failure criterion. The tensile failure process of the two joints under peeling condition was simulated. The reliability of the finite element model was verified by comparing test and simulation results, and the peeling failure behavior of the joint was analyzed. The results show that the joint has better mechanical properties when the steel sheet is used as the lower sheet, and the finite element model can better predict the failure mode and mechanical properties of the joint under peeling condition. The failure mode of the aluminum-steel joint is the separation of the rivet from the upper sheet, the stress concentration is located at the rivet tail and rivet head area of the loaded side during the peeling process, and the riveted area of the upper sheet at unloaded side first failed. The failure mode of the steel-aluminum joint is the separation of the rivet from the lower sheet, the stress concentration is located at the edge of rivet head and inside of rivet tail of the loaded side during the peeling process. Delamination damage occurred in the rivet area of the bottom sheet, and the delamination damage region extended to the rivet area of the unloaded side.

Key words: vehicle engineering, self-piercing riveting, MMC failure model, peeling simulation, failure behavior

CLC Number: 

  • U270.4

Table 1

Mechanical properties of sheet materials"

材料 密度/(kg·m-3)

弹性模

量/GPa

 泊松比 屈服强度/MPa 抗拉强度/MPa
Q235钢 7 800 200 0.3 251.9 426.6
5754铝合金 2 700 70 0.3 162.1 244.1

Fig.1

Dimensions of the rivet and die (mm)"

Fig.2

Dimensions and shape of the joints"

Fig.3

Cross sections of the joints"

Table 2

Static failure load and maximumdisplacement of each joint"

接头 静失效载荷 最大位移
均值/N 标准差 均值/mm 标准差
铝-钢 954 43.77 18.3 0.91
钢-铝 1142 57.67 22.9 1.26

Fig.4

Load-displacement curves of different joints"

Fig.5

Different failed joints for peel tests"

Table 3

Parameters of hardening formula for materials"

参 数 5754铝合金 Q235钢
A/MPa 242.9 605.3
n 0.19 0.271
C 86.1 206.6

Fig.6

Calculating flow chart of three axis stressand Rhodes angle parameter"

Table 4

Three axis stress, Rhodes angle parameter and fracture strain of materials"

材料 试件类型 应力三轴度 罗德角参数

断裂

应变
5754铝合金 单向拉伸 0.394 0.835 0.535
剪切试件 0.046 0.061 0.432
缺口10 mm 0.539 0.305 0.421
缺口6.67 mm 0.561 0.204 0.410
Q235钢 单向拉伸 0.396 0.852 0.771
剪切试件 0.075 0.010 0.752
缺口10 mm 0.517 0.404 0.663
缺口6.67 mm 0.556 0.351 0.646

Table 5

MMC model parameters of materials"

材 料 c 1 c 2 c 3 LSE
5754铝合金 0.013 2.172 0.935 0.002 2
Q235钢 0.054 1.989 0.933 0.000 1

Fig.7

Schematic diagram of parameter optimization with genetic algorithm"

Fig.8

Failure surfaces of materials"

Fig.9

Finite element model of joint"

Fig.10

Failure modes of the joints obtained bysimulation"

Fig.11

Load-displacement curves of different joints"

Fig.12

Stress cloud of aluminum-steel joint"

Fig.13

Stress and strain clouds of uppersheet at r=0.49"

Fig.14

Stress variation curve of upper sheetat failure point"

Fig.15

Stress state of joint at critical points ofload-displacement curve"

Fig.16

Stress cloud of steel-aluminum joint"

Fig.17

Stress and strain clouds of lower sheetat r=0.93"

Fig.18

Stress variation curve of lower sheetat failure point"

Fig.19

Stress state of joint at critical points ofload-displacement curve"

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