Strength estimation of self-piercing rivets using lower bound limit load analysis

This paper summarises the authors’ work on strength and failure mode estimation of self-piercing rivets (SPRs) for automotive applications. First, the static cross tension strength of an SPR joint is estimated using a lower bound limit load based strength estimator. Failure mode associated with the predicted failure strength can also be identified. It is shown that the cross tension strength of an SPR joint depends on the material and gage combinations, rivet design, die design and riveting direction. The analytical rivet strength estimator is then validated by experimental rivet strength measurements and failure mode observations from nine SPR joint populations with various material and gage combinations. Next, the estimator is used to optimise rivet strength. Two illustrative examples are presented in which rivet strength is improved by changing rivet length and riveting direction from the original manufacturing parameters.