Simulation and Parametric Study of Process‑performance of PH-SPR Steel/Aluminum Joints

doi:10.3969/j.issn.1004-132X.2026.09.029

Abstract

Abstract:

In order to systematically study the influences of processing parameters on forming quality and mechanics properties of PH-SPR steel/aluminum joints， a simulation and parametric study method was proposed considering the riveting processes and mechanics properties. Firstly， a 2D axisymmetric numerical model was established to simulate the riveting processes， and a 3D numerical model was established through 2D-3D integrated conversion method to simulate the mechanics properties of the joints. The accuracy of numerical models was verified by comparing the cross-section， failure mode， peak force， and energy absorption of tests and simulations. Secondly， based on a 2D axisymmetric model， different processing parameters were simulated and 3D joint models were generated to evaluate the corresponding mechanics properties. Finally， based on contribution and main effect analyses， the influences of processing parameters on PH-SPR joints was studied， and regression models were established to predict joint quality. The results indicate that a larger pre-drilled hole diameter leads to a decrease in peak force of the joints， but has a minimal effect on energy absorption. The rivet length is positively correlated with both undercut and mechanics performance. The established regression model may be used for predicting the forming quality and mechanics properties of PH-SPR joints， with an absolute error of less than 8.8%.

Key words: pre-holed self-piercing riveted （PH-SPR）, processing parameter, forming quality, mechanics performance, regression model

摘要：

为了系统研究工艺参数对预钻孔自冲铆接钢/铝接头的成形质量和力学性能的影响，提出了考虑铆接工艺过程和接头力学性能的仿真和参数化研究方法。建立了2D轴对称仿真模型来模拟铆接过程，并通过2D-3D一体化的转换方法建立了3D接头仿真模型来模拟接头的力学特性。通过对比试验和仿真的接头截面、失效模式、峰值载荷和能量吸收来验证仿真模型的准确性。基于2D轴对称模型模拟不同的工艺参数，并生成相应的3D接头模型来评估力学性能。基于贡献度和主效应分析研究工艺参数对预钻孔自冲铆接接头的影响，并建立了回归模型来预测接头质量。结果表明，较大的预钻孔直径会导致接头峰值力的降低，但对能量吸收的影响较小；铆钉长度与底切和力学性能正相关。建立的回归模型可用于接头成形质量和力学性能的预测，预测的绝对误差小于8.8%。

关键词: 预钻孔自冲铆接, 工艺参数, 成形质量, 力学性能, 回归模型

CLC Number:

U463.83

WANG Chao, YU Wanyuan, XIE Weijie, CHENG Aiguo, HE Zhicheng. Simulation and Parametric Study of Process‑performance of PH-SPR Steel/Aluminum Joints[J]. China Mechanical Engineering, 2026, 37(9): 2362-2371.

王超, 于万元, 解维杰, 成艾国, 何智成. 预钻孔自冲铆接钢/铝接头工艺和性能的仿真与参数化研究[J]. 中国机械工程, 2026, 37(9): 2362-2371.

Figures/Tables 20

Fig.1 Process defects and PH-SPR joint profile

Fig.2 PH-SPR process

Fig.3 Process‑performance integrated study process of PH-SPR joint

Tab.1 Mechanics properties

材料	密度ρ/（kg·m^-3）	弹性模量E/GPa	屈服应力σ_y/MPa	抗拉应力σ_m/MPa
铆钉	7.83×10³	210	1340
DP590	7.83×10³	210	381	760
6063-T6	2.70×10³	70	244	307

Fig.4 Stress-strain curves

Fig.5 Riveting equipment

Fig.6 Geometric parameters of rivet and die

Fig.7 Design and mechanical test of PH-SPR joints

Fig.8 2D axisymmetric numerical model

Fig.9 PH-SPR joint simulation model

Tab.2 Parameters of Johnson-Cook model［4，11］

材料	A/MPa	B/MPa	n	C	D₁	D₂	D₃	D₄
6063-T6	245	402	0.6286		-13.2	13.32	0.0035
DP590	392	697	0.4	0.0046	0.7	0.5	5	-0.006

Fig.10 Comparision of mechanical properties

Fig.11 Comparision of failure mode

Fig.12 Parameter design

Tab.3 Parameter range

变量	基准值	离散取值范围
模具深度D_h/mm	1.2	1.0，1.2，1.4
模具直径D_d/mm	9.0	8.5，9.0，9.5
预钻孔直径H_d/mm	5.5	5.5，6.0，6.5
铆钉长度R_l/mm	5.0	4.5，5.0，5.5，6.0
铆钉硬度R_s/GPa	1.34	1.0，1.34，1.6
上层板厚度T_t/mm	1.2	1.0，1.2，1.4，1.6
下层板厚度T_b/mm	3.0	2.0，2.5，3.0

Fig.13 Contribution and main effect diagram of process parameters to undercut and bottom thickness

Fig.14 Contribution and main effect diagram of process parameters to peak force and energy absorption

Fig.15 Main effect diagram of forming quality on peak force and energy absorption

Fig.16 Cross-section profile and failure process of joint

Tab.4 Prediction error analysis of regression model

目标	试验值	预测值	误差/%
Δu/mm	0.41	0.428	4.4
Δb/mm	0.38mm	0.389	2.4
F_max/kN	8.4	7.66	-8.8
E/J	33.5	35.9	7.2

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