鋁-鋼異種金屬板件自沖鉚接數(shù)值模擬與試驗研究

鋁-鋼異種金屬板件自沖鉚接數(shù)值模擬與試驗研究摘要：

為了研究鋁/鋼異種金屬板件自沖鉚接的工藝參數(shù)設計和接頭性能，本研究基于歐拉-拉格朗日有限元方法，建立了鋁/鋼異種金屬板件自沖鉚接的模型，并采用自適應加密網(wǎng)格技術進行網(wǎng)格優(yōu)化。隨后，通過數(shù)值模擬和實驗研究了沖釘長度、鉚釘直徑、板件厚度等因素對自沖鉚接接頭剪切強度、釘孔變形等的影響規(guī)律，以及最優(yōu)工藝參數(shù)的確定。結果表明：鋁/鋼異種金屬板件自沖鉚接的最佳工藝參數(shù)為沖釘長度為7mm，鉚釘直徑為4mm，板件厚度為1.5mm；在此工藝參數(shù)下，接頭的剪切強度和釘孔變形較小，實現(xiàn)了優(yōu)異的連接效果。

關鍵詞：鋁/鋼異種金屬板件；自沖鉚接；數(shù)值模擬；實驗研究；工藝參數(shù)

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