Finite Element Modeling and Experimental Research on Solid Self-piercing Riveting of Magnesium/Aluminum Dissimilar Materials

doi:10.3969/j.issn.1004-132X.2026.06.025

Abstract

Abstract:

Through the mechanics property calibration tests of magnesium alloy materials， the Johnson-Cook constitutive and fracture failure models were constructed， and a simulation model of the solid self-piercing riveting processes was established to analyze the plastic deformations and stress distribution of the materials in the mechanics interlock areas. A three-factor and three-level response surface experiment was carried out to reveal the main effects and interaction laws of the processing parameters， and to explore the optimization path of processing parameters. Simulation analysis and experimental results show that， the established regression model has high reliability for engineering applications and compared with the traditional self- piercing riveting， the use of solid self-piercing riveting and the optimization of riveting parameters may suppress the appearance of macroscopic cracks on the surfaces and inside the mechanics interlock deformation areas， and achieve efficient and reliable connection of magnesium/aluminum dissimilar thin- sheet materials. The maximum failure load under the optimal parameter combination obtained from the regression model is 3359 N， and the maximum energy absorption value is 5.59 J.

Key words: casting magnesium alloy, solid self-piercing riveting, constitutive model, finite element simulation, process optimization, failure load

摘要：

通过镁合金材料力学性能标定试验构建Johnson-Cook本构模型及断裂失效模型，建立实心自冲铆接成形过程仿真模型，分析机械内锁区材料的塑性变形和应力分布；开展三因素三水平响应面试验，揭示工艺参数的主效应与交互作用规律，探讨工艺参数优化路径。仿真分析与试验研究表明，建立的回归模型具有较高的工程应用可靠性；相较于传统半空心自冲铆接，采用实心自冲铆接并优化铆接工艺参数能够抑制机械内锁形变区表面及内部宏观裂纹的出现，实现镁/铝异质薄板材料高效、可靠连接。通过回归模型得到的最佳参数组合的最大失效载荷为3359 N，最大能量吸收值为5.59 J。

关键词: 铸造镁合金, 实心自冲铆, 本构模型, 有限元仿真, 工艺优化, 失效载荷

CLC Number:

TH131

ZENG Kai, ZHANG Wentao, ZHANG Hongshen, XING Baoying, HUANG Junzhi, LI Yinbo. Finite Element Modeling and Experimental Research on Solid Self-piercing Riveting of Magnesium/Aluminum Dissimilar Materials[J]. China Mechanical Engineering, 2026, 37(6): 1531-1539.

曾凯, 张文韬, 张洪申, 邢保英, 黄俊智, 李银波. 镁/铝异质材料实心自冲铆接有限元建模及试验研究[J]. 中国机械工程, 2026, 37(6): 1531-1539.

Figures/Tables 22

Tab.1 The chemical compositions of cast magnesium alloys（mass fraction）

w（Mg）	w（Al）	w（Mn）	w（Si）	w（Cu）	w（Zn）	w（Ni）
91.8~94	5.5~6.5	0.13~0.6	≤0.5	≤0.35	≤0.22	≤0.03

Fig.1 Speckle patterns and tensile strain cloud diagrams

Fig.2 Uniaxial tensile test data under quasi-static tensile conditions

Fig.3 Material hardening curve

Tab.2 Yield strengths corresponding to different strain rates

	应变率 $ε ˙$ /s $- 1$
	0.001	0.01	10	100	500	1000
屈服应力A/MPa	141	151	157	164	238	292

Tab.2 Yield strengths corresponding to different strain rates

	应变率 $ε ˙$ /s $- 1$
	0.001	0.01	10	100	500	1000
屈服应力A/MPa	141	151	157	164	238	292

Tab.3 Stress triaxiality value

试样	应力三轴度
试样	起始	断裂	平均
单轴拉伸试样	0.232	0.44	0.336
剪切试样	0	0	0
R3缺口试样	0.289	0.511	0.4

Tab.4 J-C fracture model parameters

材料	参数
材料	D₁	D₂	D₃	D₄
镁合金	0.11	$-$ 0.001 77	6.551 71	0.012 94

Tab.4 J-C fracture model parameters

材料	参数
材料	D₁	D₂	D₃	D₄
镁合金	0.11	$-$ 0.001 77	6.551 71	0.012 94

Fig.4 Assembly section， rivets， die dimensions， and mesh refinement zones in the finite element simulation model

Fig.5 Nephogram of equivalent plastic strain and stress in the riveting process

Fig.6 The force-displacement curve of riveting

Fig.7 The relative positional relationship and dimensions of the upper and lower sheets

Fig.8 The solid self-piercing riveting equipment， rivet and die

Tab.5 The level coding of test factors

因素编码	铆钳力/kN	铆接速度/（mm·s $- 1$ ）	上板厚度/mm
$-$ 1	40	5	1.5
0	45	10	2.0
1	50	15	2.5

Tab.5 The level coding of test factors

因素编码	铆钳力/kN	铆接速度/（mm·s $- 1$ ）	上板厚度/mm
$-$ 1	40	5	1.5
0	45	10	2.0
1	50	15	2.5

Tab.6 The test scheme and results

组号	铆钳力/kN	铆接速度/ （mm·s $- 1$ ）	板厚/ mm	失效载荷/N	能量吸收值/J
1	50	5	2.0	3354	5.79
2	45	5	2.5	2990	2.10
3	40	10	1.5	1545	2.80
4	45	10	2.0	2814	4.30
5	45	10	2.0	2777	4.00
6	45	10	2.0	2948	4.70
7	40	15	2.0	2940	3.36
8	45	15	1.5	1823	2.87
9	50	15	2.0	3094	4.23
10	40	10	2.5	2659	1.73
11	45	5	1.5	1884	3.71
12	40	5	2.0	2991	3.71
13	45	15	2.5	2634	1.60
14	50	10	2.5	2841	1.98
15	50	10	1.5	2275	4.67

Tab.6 The test scheme and results

组号	铆钳力/kN	铆接速度/ （mm·s $- 1$ ）	板厚/ mm	失效载荷/N	能量吸收值/J
1	50	5	2.0	3354	5.79
2	45	5	2.5	2990	2.10
3	40	10	1.5	1545	2.80
4	45	10	2.0	2814	4.30
5	45	10	2.0	2777	4.00
6	45	10	2.0	2948	4.70
7	40	15	2.0	2940	3.36
8	45	15	1.5	1823	2.87
9	50	15	2.0	3094	4.23
10	40	10	2.5	2659	1.73
11	45	5	1.5	1884	3.71
12	40	5	2.0	2991	3.71
13	45	15	2.5	2634	1.60
14	50	10	2.5	2841	1.98
15	50	10	1.5	2275	4.67

Fig.9 The sectional view of riveted joint

Fig.10 The relationship between each single factor and the failure load of the shear test

Fig.11 The influence of the interaction between riveting force and upper sheet thickness on failure load

Fig.12 The failure modes of joints and tilt angle of rivet under different sheet thickness

Fig.13 The relationship between each single factor and energy absorption value

Fig.14 The influence of the interaction between riveting force and upper plate thickness on energy absorption value

Fig.15 The warpage angle of the upper sheet under different thicknesses

Tab.7 The verification results of the prediction model

铆钳力/kN

铆接速度/

（mm·s $- 1$ ）

板材

厚度/mm

失效载荷

试验值/N

失效载荷

预测值/N

能量吸收值

试验值/J

能量吸收值

预测值/J

Tab.7 The verification results of the prediction model

铆钳力/kN

铆接速度/

（mm·s $- 1$ ）

板材

厚度/mm

失效载荷

试验值/N

失效载荷

预测值/N

1.94

3359

3361

失效载荷误差/%

能量吸收值

试验值/J

能量吸收值

预测值/J

能量吸收值误差/%

0.06

5.59

5.75

2.9

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