Performance optimization of self-piercing rivets through analytical rivet strength estimation

This paper presents the authors' work on strength optimization and failure mode prediction of self-piercing rivets (SPRs) for automotive applications. The limit load based strength estimator is used to estimate the static strength of an SPR under a cross-tension loading configuration. Failure modes associated with the estimated failure strength are also predicted. Experimental strength and failure mode observations are used to validate the model. It is shown that the strength of an SPR joint depends on the material and gage combinations, rivet design, die design, and riveting direction. The rivet strength estimator is then used to optimize the rivet strength by comparing the measured rivet strength and failure mode with the predicted ones. Two illustrative examples are used in which rivet strength is optimized by changing rivet design and riveting direction from the original manufacturing parameters.