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Numerical and experimental investigations of self-piercing riveting (SPR) and riv-bonding joints
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Liu, Yunpeng (2021) Numerical and experimental investigations of self-piercing riveting (SPR) and riv-bonding joints. PhD thesis, University of Warwick.
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Official URL: http://webcat.warwick.ac.uk/record=b3764720
Abstract
Self-piercing riveting (SPR) and Riv(et)-Bonding techniques have been widely employed for the assembly of vehicle Body-in-White (BIW) structures in the automotive industry. To deepen understanding of the two fastening methods and to facilitate their practical applications, numerical and experimental investigations of the SPR/Riv-Bonding processes were carried out in this thesis. Four problems encountered during practical applications of the SPR and Riv-Bonding were systematically studied, and the main contents are summarised below:
(1) Quality of the SPR joint is usually assessed by analysing the joint cross-sectional profile captured from the sectioned specimen. However, it is still not clear how much impact the specimen cutting position may impose on the captured shape of this joint profile, and on the joint quality evaluation result. Therefore, the influences of improper specimen cutting positions on the joint cross-sectional profile and on the measurement accuracy of joint quality indicators were systematically investigated. A strategy was also proposed accordingly to correct the measurement error of interlock, and was proved to be effective to reduce the relative interlock error to 1%~3%.
(2) It has been widely acknowledged that the die geometry can significantly influence the SPR joint quality by altering the deformation behaviours of rivet and sheets during the joining process. However, due to the limitations of experimental SPR tests, there is still not clear understanding of how different die parameters affect the events happened during the SPR process. Therefore, a two-dimensional (2D) simulation model of SPR process was firstly developed, and then employed to numerically investigate the effects of die type, die depth, die diameter and die pip height on the flare behaviour of rivet shank, the deformation behaviours of sheets and the variation trend of riveting force.
(3) Strong fluid-structure interaction (FSI) happens between the solid parts (i.e., rivet and sheets) and uncured adhesive layer during the Riv-Bonding process. Until now, it is still a challenge to numerically simulate this phenomenon. In this thesis, a 2D simulation model of Riv-Bonding process was successfully developed. The uncured adhesive (i.e., SikaPower 498) was meshed with Lagrangian elements, and its flow behaviour was approximately represented with the Ostwald-de Waele power law. Experimental Riv-Bonding tests with different configurations were conducted, and a good agreement between the simulation and experimental results was obtained. The developed simulation model was proved capable of predicting the adhesive flow behaviour, rivet and sheets deformation behaviours and riveting force during the joining process.
(4) During the Riv-Bonding process, how the adhesive layer affects the events happened in the riveting process and the final quality of riveted connection is still not clearly understood. Therefore, interrupted experimental tests with flat die and pip die were carried out in this thesis to figure out the differences between the SPR process and the corresponding Riv-Bonding process. SPR/Riv-Bonding joints with different top sheet thicknesses were also tested to study the effects of adhesive layer in joints with varying configurations. The experimental results revealed that, regardless of the die type and top sheet thickness, adhesive pockets were always formed around the joining region and thus affected the deformations of rivet and sheets. The adhesive layer imposed negative influences on the interlock formation, whilst its effects on the remaining bottom sheet thickness varied under different joint configurations.
Item Type: | Thesis (PhD) | ||||
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Subjects: | T Technology > TA Engineering (General). Civil engineering (General) T Technology > TL Motor vehicles. Aeronautics. Astronautics |
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Library of Congress Subject Headings (LCSH): | Riveted joints, Rivets and riveting, Joints (Engineering), Adhesive joints | ||||
Official Date: | September 2021 | ||||
Dates: |
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Institution: | University of Warwick | ||||
Theses Department: | School of Engineering | ||||
Thesis Type: | PhD | ||||
Publication Status: | Unpublished | ||||
Supervisor(s)/Advisor: | Liu, Xianping, 1957- | ||||
Sponsors: | University of Warwick. School of Engineering ; China Scholarship Council ; Jaguar Land Rover (Firm) | ||||
Format of File: | |||||
Extent: | xix, 172 leaves : colour illustrations | ||||
Language: | eng |
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