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  

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 王超[2] 陈涛[2] 谭海伦 Yu Wanyuan;Wang Chao;Chen Tao;Tan Hailun(College of Automotive Engineering,Liuzhou Vocational&Technical College,Liuzhou 545001,China;State Key Laboratory of Advanced Design and Manufacture for Vehicle Body,Hunan University,Changsha 410082,China)

机构地区：[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

出　　处：《锻压技术》2025年第4期183-194,共12页Forging & Stamping Technology

基　　金：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)。

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).

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[金属学及工艺—钳工工艺]