Strength modeling of Al-alloy sheet self-piercing riveting considering different failure modes

Self-piercing riveting (SPR) is an efficient joining process for bonding sheets through the interlock of rivet flaring. The strength of SPR joints is commonly measured by destructive test. In this study, the metal deformation behaviors in the SPR of aluminum alloy sheets and the mechanical behaviors of the SPR joints in the destructive tests were investigated in order to develop the general strength models of SPR joints. As the important feature in the SPR process, the rivet flaring was quantified by an empirical estimator and utilized to establish the general strength models considering the geometric dimensions of components and tools, the material properties of rivet and sheets, and the load–displacement curve of punch. The predicted strengths of the SPR specimens were verified by the experimental results. All the calculation errors are lower than 8%. Finally, an industrial internet of things (IIoT) was developed to realize the data processing and the SPR joint strength predication.