Material-structure-process-performance integrated optimization method of steel/aluminum self-piercing riveted joint

Abstract

To improve the reliability of the connection of various steel/aluminum dissimilar materials, an integrated optimization method of material-structure-process-performance is proposed to realize the optimal design of process parameters. First, the Johnson–Cook material model and failure fracture model are established to ensure the accuracy of the simulation model. Then, an integrated simulation analysis for self-piercing riveted joint forming and tensile mechanical performance is established considering the residual information of the joint forming process. Compared with the experimental results, the accuracy of the established model is higher than the model without considering the residual information. Finally, a hybrid sequence approximate optimization that comprehensively considers the forming quality and tensile mechanical performance is constructed to determine the optimal riveting parameters. Compared with the initial design, the maximum pull-out force, maximum shear force, and maximum peeling force of the optimized design for DC01 and 5754 rivets are increased by 35.66%, 8.6%, and 22.43%, respectively, and the maximum pullout force, maximum shear force and maximum peeling force of the optimized design for HC280 and 5754 rivets are increased by 1.490%, 1.292%, and 6.867%, respectively. Moreover, the accuracy and efficiency of self-piercing riveting process design are improved.