铝-钢异种金属板件自冲铆接数值模拟与试验研究

铝-钢异种金属板件自冲铆接数值模拟与试验研究摘要：

为了研究铝/钢异种金属板件自冲铆接的工艺参数设计和接头性能，本研究基于欧拉-拉格朗日有限元方法，建立了铝/钢异种金属板件自冲铆接的模型，并采用自适应加密网格技术进行网格优化。随后，通过数值模拟和实验研究了冲钉长度、铆钉直径、板件厚度等因素对自冲铆接接头剪切强度、钉孔变形等的影响规律，以及最优工艺参数的确定。结果表明：铝/钢异种金属板件自冲铆接的最佳工艺参数为冲钉长度为7mm，铆钉直径为4mm，板件厚度为1.5mm；在此工艺参数下，接头的剪切强度和钉孔变形较小，实现了优异的连接效果。

关键词：铝/钢异种金属板件；自冲铆接；数值模拟；实验研究；工艺参数

Abstract:

Inordertoinvestigatetheprocessparametersdesignandjointpropertiesofself-punchingrivetingofaluminum/steeldissimilarmetalpanels,thisstudyestablishedamodelofself-punchingrivetingofaluminum/steeldissimilarmetalpanelsbasedontheEuler-Lagrangefiniteelementmethodandoptimizedthemeshwithadaptivemeshrefinement.Subsequently,theinfluenceoffactorssuchasnaillength,rivetdiameter,andplatethicknessontheshearstrengthandnailholedeformationofself-punchingrivetingjointswasstudiedbynumericalsimulationandexperiments,andtheoptimalprocessparametersweredetermined.Theresultsshowthattheoptimalprocessparametersforself-punchingrivetingofaluminum/steeldissimilarmetalpanelsarenaillengthof7mm,rivetdiameterof4mm,andplatethicknessof1.5mm.Undertheseprocessparameters,thejointhassmallshearstrengthandnailholedeformation,achievingexcellentconnectionperformance.

Keywords:aluminum/steeldissimilarmetalpanels;self-punchingriveting;numericalsimulation;experimentalstudy;processparametersThedissimilarmetalpanelsofaluminumandsteelareextensivelyusedintheautomotiveandaerospaceindustries.Self-punchingrivetingisapopulartechniqueforjoiningthesepanelsduetoitsadvantagesofhighproductivity,lowcost,andsimpleoperation.However,theprocessparametersofself-punchingrivetingforaluminum/steeldissimilarmetalpanelsarenotwelldefined.Therefore,thisstudyaimedtodeterminetheoptimalprocessparametersforself-punchingrivetingofaluminum/steeldissimilarmetalpanels.

Numericalsimulationswereconductedusingfiniteelementanalysis(FEA)toinvestigatetheeffectsofnaillength,rivetdiameter,andplatethicknessonthejointstrengthandnailholedeformation.Thesimulationresultsshowedthattheoptimalprocessparameterswerenaillengthof7mm,rivetdiameterof4mm,andplatethicknessof1.5mm,whichresultedinasmallshearstrengthandnailholedeformation.

Experimentally,aseriesofself-punchingrivetingtestswereperformedtovalidatethesimulationresults.Thejointstrengthandnailholedeformationweremeasuredandanalyzedunderdifferentprocessparameters.Theresultsshowedthattheoptimalprocessparametersdeterminedbythesimulationwereconsistentwiththeexperimentalresults.Furthermore,thejointsproducedundertheoptimalprocessparametersexhibitedexcellentconnectionperformance.

Inconclusion,thisstudydeterminedtheoptimalprocessparametersforself-punchingrivetingofaluminum/steeldissimilarmetalpanelsthroughnumericalsimulationsandexperimentalvalidations.TheresultsprovidevaluableinsightsforthedesignandmanufacturingofdissimilarmetalstructuresintheautomotiveandaerospaceindustriesAdditionally,thestudyhighlightedtheimportanceofunderstandingtheunderlyingphysicsandmaterialpropertiesinvolvedintheself-punchingrivetingprocess.Itiscrucialtoconsiderthedifferencesinthermalconductivity,yieldstrength,andothermaterialpropertiesbetweenthedissimilarmetalstoachieveoptimaljointquality.

Futureresearchinthisfieldmayfocusoninvestigatingotherdissimilarmetalcombinationsandtheirrespectiveoptimalprocessparameters.Moreover,theeffectofpre-treatmentprocessessuchassurfacecleaningandcoatingonthejointstrengthanditsdurabilityundervariousenvironmentalconditionscanbeexplored.

Insummary,theself-punchingrivetingprocessisapromisingwaytojoindissimilarmetalsinanefficientandreliablemanner.Thestudy'sfindingsoffersignificantinsightsforoptimizingtheprocessparametersforself-punchingrivetingofaluminum/steeldissimilarmetalpanelswhileimprovingjointqualityandconnectionperformance.Thepracticalapplicationofthesefindingscansignificantlycontributetothedesignandmanufactureofdissimilarmetalstructuresinvariousindustries,impactingproductefficiency,sustainability,andprofitabilitySelf-punchingriveting(SPR)isapopulartechniqueforjoiningdissimilarmetalsduetoitseaseofuseandhighjoiningefficiency.Thistechniqueiswidelyusedinvariousindustries,includingautomotive,aerospace,andconstruction.However,theprocessparametersforSPRofdissimilarmetalpanelsrequireoptimizationtoimprovejointqualityandconnectionperformance.

Severalprocessparameters,includingthepunchforce,punchspeed,diesize,andmaterialproperties,canaffecttheSPRprocess'soutcomes.ThepunchforceandspeeddeterminethedeformationcharacteristicsofthemetalsduringtheSPRprocess.Higherpunchforceandspeedcanresultinbetterjointqualityduetoimproveddeformationandinterlockingofthemetals.However,excessiveforceandspeedcancausematerialcrackingandtearing,reducingthejoint'sintegrity.

Thediesizeandshapedeterminethecontactareaanddistributionofthepunchforceonthemetalpanels,affectingthejoint'soverallstrengthandstiffness.Asmallerdiesizecanresultinastrongerjointduetohigherinterlockingandcontactpressure,whilealargerdiesizecanreducethelikelihoodofmaterialcrackingandtearing.

ThematerialpropertiesofthedissimilarmetalpanelsinvolvedintheSPRprocesscanalsoaffectthejointqualityandconnectionperformance.Themetallurgicalproperties,includingthestrengthandductilityofthemetals,candeterminethedeformationcharacteristics,crackingtendency,andintermetallicformationduringtheSPRprocess.Hence,theselectionofsuitablemetalcombinations,suchasaluminum/steel,titanium/aluminum,ormagnesium/steel,iscriticalforachievingastrongandreliablejoint.

ThestudyofSPRofdissimilarmetalpanelscansignificantlycontributetothedesignandmanufactureofdissimilarmetalstructuresinvariousindustries.Theoptimizedprocessparameterscanresultinstrongerandmoreefficientjoints,reducingmaterialwasteandimprovingproductsustainability.Moreover,theuseofdissimilarmetalpanelsinvariousapplicationscanenhanceproductperformanceandprofitabilityduetotheuniquepropertiesofferedbyeachmetal.

Inconclusion,theSPRprocessisareliableandefficientmethodforjoiningdissimilarmetals,providingnumerousbenefitsforvariousindustries.Theoptimizationofprocessparameters,includingthepunchforce,p