Forging Process Design of Self-Piercing Rivet for Joining dissimilar Sheet Metals

Abstract: Self-piercing rivet is sheet joining method. It is being used more to join aluminum alloy sheets.Self-piercing riveting is a large-deformation process that involves piercing. The self-piercing rivet, under thepress from the punch, pierces the top sheet and forms a mechanical interlock with the bottom sheet. In thisstudy, forging process was designed for manufacturing self-piercing rivet. The forging process has been simulated by using commercial FEM code DEFORM-2D. In simulation of forging process for manufacturing rivet, process sequence, formability, forging load, and distributions of stress and strain wereinvestigated. The suitable forging process could be designed by comparisons of simulation results. The developed process consists of four stages: upsetting, first chamfering, back extrusion, and second chamfering. The simulated results for forging process were confirmed by experimental trials with the sameconditions. Key words: Self-piercing rivet, Forging process, Finite Element Method, DEFORM-2D