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Research Papers

Finite Element Analysis of Self-Pierce Riveting in Magnesium Alloys Sheets

[+] Author and Article Information
J. F. C. Moraes, J. B. Jordon

Department of Mechanical Engineering,
The University of Alabama,
Tuscaloosa, AL 35401

D. J. Bammann

Department of Mechanical Engineering,
Mississippi State University,
Mississippi State, MS 39762

Contributed by the Materials Division of ASME for publication in the JOURNAL OF ENGINEERING MATERIALS AND TECHNOLOGY. Manuscript received January 21, 2014; final manuscript received November 6, 2014; published online December 12, 2014. Assoc. Editor: Marwan K. Khraisheh.

J. Eng. Mater. Technol 137(2), 021002 (Apr 01, 2015) (9 pages) Paper No: MATS-14-1016; doi: 10.1115/1.4029032 History: Received January 21, 2014; Revised November 06, 2014; Online December 12, 2014

Conventional fusion joining methods, such as resistance spot welding (RSW), have been demonstrated to be ineffective for magnesium alloys. However, self-pierce riveting (SPR) has recently been shown as an attractive joining technique for lightweight metals, including magnesium alloys. While the SPR joining process has been experimentally established on magnesium alloys through trial and error, this joining process is not fully developed. As such, in this work, we explore simulation techniques for modeling the SPR process that could be used to optimize this joining method for magnesium alloys. Due to the process conditions needed to rivet the magnesium sheets, high strain rates and adiabatic heat generation are developed that require a robust material model. Thus, we employ an internal state variable (ISV) plasticity material model that captures strain-rate and temperature dependent deformation. In addition, we explore various damage modeling techniques needed to capture the piercing process observed in the joining of magnesium alloys. The simulations were performed using a two-dimensional axisymmetric model with various element deletion criterions resulting in good agreement with experimental data. The simulations results of this study show that the ISV material model is ideally suited for capturing the complex physics of the plasticity and damage observed in the SPR of magnesium alloys.

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Figures

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Fig. 1

Schematic of the SPR process steps: (1) clamping, (2) piercing, (3) mechanical interlock obtained, and (4) punch release

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Fig. 2

Comparison between the experimental and the ISV model correlation results of a tensile test

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Fig. 3

SPR die and rivet geometry

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Fig. 4

Initial configuration of the axisymmetric SPR finite element model

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Fig. 5

The SPR process at different time steps: (a) effective stress, (b) effect strain, and (c) final shape of the FEA superimposed on the experimental results. Experimental image adapted from Ref. [9].

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Fig. 6

Comparison between numerical analysis and experimental results [5] for of the final shape of the SPR: (a) isothermal and strain to failure based on uniaxial tensile results (55%); (b) isothermal, strain to failure of 250% on top sheet; (c) Isothermal and strain to failure of 250% on top and bottom sheets; (d) adiabatic, strain to failure of 250% on top sheet; (e) adiabatic and failure based on damage criterion on top sheet; and (f) adiabatic and failure based on damage criterion on top and bottom sheets. Experimental images adapted from Ref. [9].

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Fig. 7

History plot of one element from top sheet: (a) an element selected in top sheet, (b) temperature, and (c) von Mises Stress

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Fig. 8

Comparison between numerical analysis and experimental results showing crack prediction at room temperature for SPR of magnesium alloy: (a) location of the elements deleted on the final configuration of the joint during the simulation, (b) elements deleted from the simulation, and (c) bottom of the joint obtained experimentally. Adapted from Ref. [9].

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