Thermomechanical modeling of the metallic rivet in friction riveting of amorphous thermoplastics

Abstract

The present work aims for an initial computational simulation with finite element analysis of the friction riveting process. Knowledge and experimental data from friction riveting of AA2024-T351 and polyetherimide supported the computational simulation. Friction riveting is a friction-based joining technology capable of connecting multiple dissimilar overlapping materials in a fast and simple manner. In this paper, the plastic deformation of the metallic rivet, process heat input, and temperature distribution were modeled and simulated. The plastic deformation of the metallic rivet is of key importance in creating the mechanical interlocking and main joining mechanism between the parts, being this the focus of this work. The influence of the polymeric material was considered a dynamic boundary condition via heat input and pressure profiles applied to the rivet. The heat input, mainly generated by viscous dissipation within the molten polymer, was analytically estimated. Three experimental conditions were simulated. The heat flux values applied in modeling of the different conditions were determined (8.2, 9.1, and 10.2 W/mm2). These yielded distinct plastic deformations characterized by a diameter of the rivet tip, from the initial 5 mm to 6.2, 7.0, and 9.3 mm. The maximum temperatures were 365, 395, and 438 °C, respectively.

Influence of Friction Riveting Parameters on the Dissimilar Joint Formation and Strength

“…The results confirmed the occurrence of an undesired failure in the rivet pull-out test, which was analysed in detail using FE modelling. Cipriano et al [ 34 ] continued the research with the thermomechanical modelling of the friction riveting process. They analysed, in detail, the plastic deformation of the rivet, the temperature distribution and the heat input to simulate the process and provide a better understanding of it.…”

Fatigue and fracture of ultrasonically welded aluminum alloys to carbon fiber reinforced thermoplastics

“…In addition, depending on the joining kinematics, different bonding mechanisms can be achieved through the combination of adhesive and cohesive bonding. [6][7][8] Among other technologies, research activities for joining similar and dissimilar materials include laser direct joining, 9,10 a variety of different friction-assisted joining processes, 11,12 adhesive bonding technologies, 13 and ultrasonic welding for different combinations of dissimilar materials. [14][15][16][17][18] Ultrasonic welding is a promising technology for joining hybrid light metal to FRP structures.…”