Self-piercing riveting (SPR) is a high-speed fastening process that can join similar and dissimilar sheet materials without the need for pre-processing such as drilling or punching. During SPR processes, two overlapping sheets are joined by a rivet. The upper sheet is punched first by the rivet and then the lower sheet is deformed between the rivet and the die, creating a mechanical interlock. In this study, self-piercing riveting of aluminum alloy and carbon fiber reinforced polymer composites (CFRP) sheets was analysed using finite element simulations. For the finite element simulation of SPR processes, the orthogonal elasticity, the fracture model, and the cohesive zone model were used for describing the behaviour of CFRP. For validation of the composite material model, the punching process of CFRP was performed and the results were compared with FE predictions. The SPR process of the aluminum alloy and CFRP was simulated numerically and the performance of the joint was evaluated.
The equivalence between the localization criteria and the fracture criteria was validated as a forming limit for the proper prediction of failure induced by severe strain localization in the two-step hybrid forming process of 7xxx series aluminum alloy sheets at the elevated temperature. In the previous researches, an extensive and systematic method combined with sophisticated material characterization had been revisited as the localization criterion to estimate the onset of the failure without any fracture criteria. As for the fracture criteria, a deformation path and effective strain-rate sensitive fracture criterion was utilized. In the event of failure occurrence with abrupt strain localization, which has been traditionally known as the localization criteria dominant case, the fracture criteria can replace the localization criteria as a forming limit.
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