Validation of riveting process
3 likes846 views
This document describes a finite element analysis simulation of a riveting process in ANSYS and compares the results to experimental data. The simulation modeled a rivet being driven into a sheet metal joint. Material properties, boundary conditions, and a displacement-controlled loading process were defined. The results for bulge diameter and protruding rivet height matched well with experimental testing, with less than 2.13% difference. This validated the ability of the ANSYS simulation to accurately model the riveting process.
![Problem Statement
• Objective:
To benchmark riveting process in ANSYS with the
experimental results[1].
• To simulate a riveting process.
– A rivet is driven into sheet joint
© 2010 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary
– A rivet is driven into sheet joint
– Other end of the rivet is constraint using a rigid
support
• Output
– Dmax, diameter of the bulge
– H, Final protruding height
[1] Amarendra, .A (2006), “A Finite Element and Experimental Investigation on the Fatigue of Riveted Lap Joints in Aircraft Applications,” Phd Thesis, School of Mechanical Engineering, Georgia
Institute of Technology.](https://image.slidesharecdn.com/validationofrivetingprocess-160906184230/85/Validation-of-riveting-process-2-320.jpg)
![Material definition
Following material properties were used for the respective parts:
• Rivet : 21174-T4 AL Alloy
• Sheet 2024-T3 Al Alloy
A tabulated stress strain input data was provide based on the equation given
below:
σtrue = C(εtrue
m)
Isotropic hardening was considering during the simulation
© 2010 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary
Isotropic hardening was considering during the simulation
Material Elastic Properties Flow Stress Parameters
Young’s
Modulus (GPa)
Poisson’
s ratio
Strain Range C (MPa) m
21174-T4 AL 71.7 0.33 εy≤εtrue≤3 551.58[2,3] 0.15[2,3]
2024-T3 AL 72.4 0.33 εy≤εtrue≤0.02 765[1] 0.14[1]
0.02≤εtrue≤3 744[1] 0.164[1]
[1] Amarendra, .A (2006), “A Finite Element and Experimental Investigation on the Fatigue of Riveted Lap Joints in Aircraft Applications,” Phd Thesis, School of Mechanical Engineering, Georgia
Institute of Technology.
[2] Szolwinski, M.P., Farris, T.N. (2000). “Linking riveting process parameters to the fatigue performance of riveted aircraft structures,” Journal of Aircraft, Vol.37, No.1, pp. 130-135.
[3] Bajracharya,. B (2006),“Effect of Variations of Riveting Process on The Quality of Riveted Joints,” Masters Thesis, Department of Industrial and Manufacturing, Wichita State University.](https://image.slidesharecdn.com/validationofrivetingprocess-160906184230/85/Validation-of-riveting-process-5-320.jpg)
![Dmax Result Comparison
8.5
9
9.5
10
10.5
11
11.5
Dmax(mm)
Dmax Result Comparison
ANSYS
Exp
© 2010 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary
8
25 30 35 40 45 50 55 60
Squeeze Force (KN)
Squeeze
Force,
ANSYS
(KN)
Squeeze
Force,
Exp[1] (KN)
Dmax
(mm)
Ansys
Dmax
(mm)
Exp[1]
% diff
(ANSYS)
26.90 26.69 8.6454 8.559 1.01
35.67 35.56 9.6108 9.525 0.9
45.02 44.48 10.3766 10.16 2.13
53.80 53.37 10.9426 10.795 1.37
[1] Amarendra, .A (2006), “A Finite Element and Experimental Investigation on the Fatigue of Riveted Lap Joints in Aircraft Applications,” Phd Thesis, School of Mechanical Engineering, Georgia
Institute of Technology.](https://image.slidesharecdn.com/validationofrivetingprocess-160906184230/85/Validation-of-riveting-process-13-320.jpg)
![Final Protruding Height Comparison
3.5
4
4.5
5
5.5
6
ProtrudingHeight(mm)
Protruding Height (H) Comparison
ANSYS
Exp
© 2010 ANSYS, Inc. All rights reserved. 14 ANSYS, Inc. Proprietary
3
25 35 45 55 65
Squeeze Force (KN)
Squeeze
Force,
ANSYS
(KN)
Squeeze
Force,
Exp[1] (KN)
H (mm)
Ansys
H (mm)
Exp[1]
% diff
(ANSYS)
26.90 26.69 5.797 5.796 0.017
35.67 35.56 4.66 4.59 1.53
45.02 44.48 3.93 4 1.75
53.80 53.37 3.46 3.49 0.86
[1] Amarendra, .A (2006), “A Finite Element and Experimental Investigation on the Fatigue of Riveted Lap Joints in Aircraft Applications,” Phd Thesis, School of Mechanical Engineering, Georgia
Institute of Technology.](https://image.slidesharecdn.com/validationofrivetingprocess-160906184230/85/Validation-of-riveting-process-14-320.jpg)
![Refrences:
[1] Amarendra, .A (2006), “A Finite Element and Experimental Investigation on
the Fatigue of Riveted Lap Joints in Aircraft Applications,” Phd Thesis,
School of Mechanical Engineering, Georgia Institute of Technology.
[2] Szolwinski, M.P., Farris, T.N. (2000). “Linking riveting process parameters
to the fatigue performance of riveted aircraft structures,” Journal of Aircraft,
Vol.37, No.1, pp. 130-135.
© 2010 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary
Vol.37, No.1, pp. 130-135.
[3] Bajracharya,. B (2006),“Effect of Variations of Riveting Process on The
Quality of Riveted Joints,” Masters Thesis, Department of Industrial and
Manufacturing, Wichita State University.](https://image.slidesharecdn.com/validationofrivetingprocess-160906184230/85/Validation-of-riveting-process-16-320.jpg)
Validation of riveting process
- 1. Validation of RivetingValidation of Riveting processprocess Validation of RivetingValidation of Riveting processprocess --AshutoshAshutosh SrivastavaSrivastava --GunjanGunjan VermaVerma --VinayVinay CarpenterCarpenter --AshutoshAshutosh SrivastavaSrivastava --GunjanGunjan VermaVerma --VinayVinay CarpenterCarpenter © 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary© 2010 ANSYS, Inc. All rights reserved. 1 ANSYS, Inc. Proprietary
- 2. Problem Statement • Objective: To benchmark riveting process in ANSYS with the experimental results[1]. • To simulate a riveting process. – A rivet is driven into sheet joint © 2010 ANSYS, Inc. All rights reserved. 2 ANSYS, Inc. Proprietary – A rivet is driven into sheet joint – Other end of the rivet is constraint using a rigid support • Output – Dmax, diameter of the bulge – H, Final protruding height [1] Amarendra, .A (2006), “A Finite Element and Experimental Investigation on the Fatigue of Riveted Lap Joints in Aircraft Applications,” Phd Thesis, School of Mechanical Engineering, Georgia Institute of Technology.
- 3. Problem Configuration Top View of plates Rivet Close-up © 2010 ANSYS, Inc. All rights reserved. 3 ANSYS, Inc. Proprietary Top View of plates Side View of specimen Rivet Close-up
- 4. Geometry Punch Rivet Bottom Plate 2mm thick 3.175 11.9 © 2010 ANSYS, Inc. All rights reserved. 4 ANSYS, Inc. Proprietary Bottom Plate 2mm thick Top Plate 2mm thick 34.9 5.475 11.9 14.2 All Dimensions are in mm
- 5. Material definition Following material properties were used for the respective parts: • Rivet : 21174-T4 AL Alloy • Sheet 2024-T3 Al Alloy A tabulated stress strain input data was provide based on the equation given below: σtrue = C(εtrue m) Isotropic hardening was considering during the simulation © 2010 ANSYS, Inc. All rights reserved. 5 ANSYS, Inc. Proprietary Isotropic hardening was considering during the simulation Material Elastic Properties Flow Stress Parameters Young’s Modulus (GPa) Poisson’ s ratio Strain Range C (MPa) m 21174-T4 AL 71.7 0.33 εy≤εtrue≤3 551.58[2,3] 0.15[2,3] 2024-T3 AL 72.4 0.33 εy≤εtrue≤0.02 765[1] 0.14[1] 0.02≤εtrue≤3 744[1] 0.164[1] [1] Amarendra, .A (2006), “A Finite Element and Experimental Investigation on the Fatigue of Riveted Lap Joints in Aircraft Applications,” Phd Thesis, School of Mechanical Engineering, Georgia Institute of Technology. [2] Szolwinski, M.P., Farris, T.N. (2000). “Linking riveting process parameters to the fatigue performance of riveted aircraft structures,” Journal of Aircraft, Vol.37, No.1, pp. 130-135. [3] Bajracharya,. B (2006),“Effect of Variations of Riveting Process on The Quality of Riveted Joints,” Masters Thesis, Department of Industrial and Manufacturing, Wichita State University.
- 6. Material definition contd.. 4.00E+08 5.00E+08 6.00E+08 7.00E+08 Stress(Pa) Hardening curve 21174-T4 AL alloy © 2010 ANSYS, Inc. All rights reserved. 6 ANSYS, Inc. Proprietary 0.00E+00 1.00E+08 2.00E+08 3.00E+08 4.00E+08 -0.50 0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 Stress(Pa) Plastic Strain (mm/mm)
- 7. Material definition contd.. 6.00E+08 7.00E+08 8.00E+08 9.00E+08 1.00E+09 Stress(Pa) Hardening curve 2024-T3 AL alloy © 2010 ANSYS, Inc. All rights reserved. 7 ANSYS, Inc. Proprietary 0.00E+00 1.00E+08 2.00E+08 3.00E+08 4.00E+08 5.00E+08 -0.5 0 0.5 1 1.5 2 2.5 3 3.5 Stress(Pa) Plastic Strain (mm/mm)
- 8. Boundary Conditions Fix X direction displacement on rivet edge Fix X direction displacement & apply displacement in Y direction to the puncher © 2010 ANSYS, Inc. All rights reserved. 8 ANSYS, Inc. Proprietary Fix Y direction displacement at plates side Fix Y direction displacement at rivet head
- 9. Analysis Settings and procedure • Load was applied gradually in two steps. – In the first step predetermined displacement was applied – In the second step the punch was displaced in reverse direction to simulate spring-back action of the rivet. • All contacts were considered as frictional contact (frictional coefficient as 0.2) except the one between the plates which was assumed as © 2010 ANSYS, Inc. All rights reserved. 9 ANSYS, Inc. Proprietary as 0.2) except the one between the plates which was assumed as bonded for simplicity. • Force probe was used to determine the squeeze force. • Load displacement graph was plotted for each case.
- 10. RESULTS © 2010 ANSYS, Inc. All rights reserved. 10 ANSYS, Inc. Proprietary RESULTS
- 11. UX Direction Displacement © 2010 ANSYS, Inc. All rights reserved. 11 ANSYS, Inc. Proprietary F = 26.9 KN Dmax = 8.6454mm F = 35.67 KN Dmax = 9.6108mm F = 45.02 KN Dmax = 10.3766mm F = 53.804 KN Dmax = 10.9426mm
- 12. UY Direction Displacement © 2010 ANSYS, Inc. All rights reserved. 12 ANSYS, Inc. Proprietary F = 26.9 KN H = 5.796mm F = 35.67 KN H = 4.66mm F = 45.02 KN H = 3.93mm F = 53.804 KN H = 3.46mm
- 13. Dmax Result Comparison 8.5 9 9.5 10 10.5 11 11.5 Dmax(mm) Dmax Result Comparison ANSYS Exp © 2010 ANSYS, Inc. All rights reserved. 13 ANSYS, Inc. Proprietary 8 25 30 35 40 45 50 55 60 Squeeze Force (KN) Squeeze Force, ANSYS (KN) Squeeze Force, Exp[1] (KN) Dmax (mm) Ansys Dmax (mm) Exp[1] % diff (ANSYS) 26.90 26.69 8.6454 8.559 1.01 35.67 35.56 9.6108 9.525 0.9 45.02 44.48 10.3766 10.16 2.13 53.80 53.37 10.9426 10.795 1.37 [1] Amarendra, .A (2006), “A Finite Element and Experimental Investigation on the Fatigue of Riveted Lap Joints in Aircraft Applications,” Phd Thesis, School of Mechanical Engineering, Georgia Institute of Technology.
- 14. Final Protruding Height Comparison 3.5 4 4.5 5 5.5 6 ProtrudingHeight(mm) Protruding Height (H) Comparison ANSYS Exp © 2010 ANSYS, Inc. All rights reserved. 14 ANSYS, Inc. Proprietary 3 25 35 45 55 65 Squeeze Force (KN) Squeeze Force, ANSYS (KN) Squeeze Force, Exp[1] (KN) H (mm) Ansys H (mm) Exp[1] % diff (ANSYS) 26.90 26.69 5.797 5.796 0.017 35.67 35.56 4.66 4.59 1.53 45.02 44.48 3.93 4 1.75 53.80 53.37 3.46 3.49 0.86 [1] Amarendra, .A (2006), “A Finite Element and Experimental Investigation on the Fatigue of Riveted Lap Joints in Aircraft Applications,” Phd Thesis, School of Mechanical Engineering, Georgia Institute of Technology.
- 15. Conclusion • The whole process was setup in workbench environment without any assistance of command snippet. • All the four cases were setup in a single project format, thus eliminating the need of four different files. • ANSYS numerical results match with experimental results © 2010 ANSYS, Inc. All rights reserved. 15 ANSYS, Inc. Proprietary • ANSYS numerical results match with experimental results well within the norms – A maximum difference of 2.13% was observed for the final deformed rivet diameter. – A maximum difference of 1.75% was observed for the final protruding height
- 16. Refrences: [1] Amarendra, .A (2006), “A Finite Element and Experimental Investigation on the Fatigue of Riveted Lap Joints in Aircraft Applications,” Phd Thesis, School of Mechanical Engineering, Georgia Institute of Technology. [2] Szolwinski, M.P., Farris, T.N. (2000). “Linking riveting process parameters to the fatigue performance of riveted aircraft structures,” Journal of Aircraft, Vol.37, No.1, pp. 130-135. © 2010 ANSYS, Inc. All rights reserved. 16 ANSYS, Inc. Proprietary Vol.37, No.1, pp. 130-135. [3] Bajracharya,. B (2006),“Effect of Variations of Riveting Process on The Quality of Riveted Joints,” Masters Thesis, Department of Industrial and Manufacturing, Wichita State University.