Rivet Structural Design and Process Optimization for the Double-Sided Countersunk Riveting of Composite Wedge Structures

Abstract

Within the double-sided countersunk riveting process of aircraft wings with a composite wedge structure, riveting consistency is poor, and composite damage is severe, which seriously affects the performance and reliability of the aircraft structure. This paper used the principal stress method to establish a stress model of countersunk riveting, and, based on the analysis of the stress on the structure during the pressure-riveting process, a composite structure rivet was designed. A finite element simulation model of the double-sided countersunk riveting of composite wedge structures’ composite rivets was established. The influences of the structure and the matching parameters of composite rivets on both the plastic flow of pressure riveting and the compressive stress of the structure during the pressure-riveting process were analyzed. The structural parameters and riveting process of composite rivets were optimized. The results show that the composite rivet structure could significantly reduce the contact-compressive stress at the riveting joint by more than 20%, thereby reducing the damage caused by the riveting to the composite material. For 4 mm rivets, an aperture of 4.04~4.06 mm can achieve precise relative interference riveting at 0.6% to 1.0%. Employing a 2.6 mm rivet elongation can exactly fill the countersunk hole of the wedge.