锻压技术

自冲铆接和预穿孔自冲铆接的钢/铝板成形质量的数值模拟研究

英文标题：Numerical simulation study on forming quality for steel/aluminium sheet by self-piercing riveting and pre-punched self-piercing riveting

作者：于万元1 王超2 陈涛2 谭海伦2

单位：(1. 柳州职业技术学院汽车工程学院广西柳州 545001 2. 湖南大学汽车车身先进设计制造国家重点实验室湖南长沙 410082)

关键词：钢/铝板传统自冲铆接预穿孔自冲铆接成形质量底切值

分类号：TG938

出版年,卷(期):页码：2025,50(4):183-194

摘要：

对比研究了传统自冲铆接(C-SPR)和预穿孔自冲铆接(PH-SPR)在连接钢/铝板时的成形差异，分析铆钉硬度、铆钉和模具的几何尺寸、板材材料和厚度对成形质量的影响。基于LS-DYNA建立了SPR工艺铆接过程的二维轴对称有限元模型。通过比较试验和模拟的SPR接头截面形状，验证了数值模型的准确性。结果表明：当铆钉的屈服强度为0.9~1.3 GPa时，PH-SPR接头具有更高的底切值，同时PH-SPR工艺需要选择合适的铆钉长度来保证成形质量。C-SPR和PH-SPR接头的底部厚度受模具尺寸参数的影响较底切值明显。PH-SPR在连接不同材料组合时，具备更高的通用性，而C-SPR仅适合连接屈服强度低于500 MPa的板材。C-SPR和PH-SPR均适合连接较薄(厚度≤1.6 mm)的上层板。

The forming differences between conventional self-piercing riveting (C-SPR) and pre-punched self-piercing riveting (PH-SPR) in joining steel/aluminum sheets were compared and studied， and the influences of rivet hardness， geometric dimensions of rivets and dies， sheet material and thickness on the forming quality were analyzed. Then， a two-dimensional (2D) axisymmetric finite element model of the SPR riveting process was established by LS-DYNA， and the accuracy of the numerical model was validated by comparing the tested and simulated cross-sectional shape of the SPR joint. The results show that when the yield strength of rivet is 0.9~1.3 GPa， PH-SPR has a higher undercut value. At the same time， PH-SPR process needs to select a suitable rivet length to ensure the forming quality. The bottom thickness of C-SPR and PH-SPR joints is more significantly affected by the die size parameters than the undercut value. PH-SPR has higher versatility when connecting different material combinations， while C-SPR is only suitable for connecting sheet with a yield strength of less than 500 MPa.Both C-SPR and PH-SPR are suitable for connecting thinner upper sheets (thickness≤1.6 mm).

基金项目：

基金项目:广西高校中青年教师科研基础能力提升项目(2024KY1097)；广西科技重大专项(桂科AA23062064)；湖南省自然科学基金资助项目(2023JJ40153)

作者简介：于万元(1987-)，女，硕士，工程师

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