FEM Simulation of the Riveting Process and Structural Analysis of Low-Carbon Steel Tubular Rivets Fracture
Riveted joints are a common way to connect elements and subassemblies in the automotive industry. In the assembly process, tubular rivets are loaded axially with ca. 3 kN forces, and these loads can cause cracks and delamination in the rivet material. Such effects at the quality control stage disqua...
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-01-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/15/1/374 |
| _version_ | 1797498371246653440 |
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| author | Jaroslaw Jan Jasinski Michal Tagowski |
| author_facet | Jaroslaw Jan Jasinski Michal Tagowski |
| author_sort | Jaroslaw Jan Jasinski |
| collection | DOAJ |
| description | Riveted joints are a common way to connect elements and subassemblies in the automotive industry. In the assembly process, tubular rivets are loaded axially with ca. 3 kN forces, and these loads can cause cracks and delamination in the rivet material. Such effects at the quality control stage disqualify the product in further assembly process. The article presents an analysis of the fracture mechanism of E215 low-carbon steel tubular rivets used to join modules of driver and passenger safety systems (airbags) in vehicles. Finite element method (FEM) simulation and material testing were used to verify the stresses and analysis of the rivet fracture. Numerical tests determined the state of stress during rivet forming using the FEM-EA method based on the explicit integration of central differences. Light microscopy (LM), scanning electron microscopy (SEM) and chemical composition analysis (SEM-EDS) were performed to investigate the microstructure of the rivet material and to analyze the cracks. Results showed that the cause of rivet cracking is the accumulation and exceeding of critical tensile stresses in the rivet flange during the tube processing and the final riveting (forming) process. Moreover, it was discovered that rivet fracture is largely caused by structural defects (tertiary cementite Fe,Mn<sub>3</sub>C<sub>III</sub> along the boundaries of prior austenite grains) in the material resulting from the incorrectly selected parameters of the final heat treatment of the prefabricate (tube) from which the rivet was produced. The FEM simulation of the riveting and structural characterization results correlated well, so the rivet forming process and fracture mechanism could be fully investigated. |
| first_indexed | 2024-03-10T03:32:29Z |
| format | Article |
| id | doaj.art-1b18c1cc837347e7a618ca176b532bc0 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T03:32:29Z |
| publishDate | 2022-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-1b18c1cc837347e7a618ca176b532bc02023-11-23T11:52:19ZengMDPI AGMaterials1996-19442022-01-0115137410.3390/ma15010374FEM Simulation of the Riveting Process and Structural Analysis of Low-Carbon Steel Tubular Rivets FractureJaroslaw Jan Jasinski0Michal Tagowski1Materials Research Laboratory, National Centre for Nuclear Research, 05-400 Otwock, PolandFaculty of Mechanical Engineering and Computer Science, Czestochowa University of Technology CUT, 42-200 Czestochowa, PolandRiveted joints are a common way to connect elements and subassemblies in the automotive industry. In the assembly process, tubular rivets are loaded axially with ca. 3 kN forces, and these loads can cause cracks and delamination in the rivet material. Such effects at the quality control stage disqualify the product in further assembly process. The article presents an analysis of the fracture mechanism of E215 low-carbon steel tubular rivets used to join modules of driver and passenger safety systems (airbags) in vehicles. Finite element method (FEM) simulation and material testing were used to verify the stresses and analysis of the rivet fracture. Numerical tests determined the state of stress during rivet forming using the FEM-EA method based on the explicit integration of central differences. Light microscopy (LM), scanning electron microscopy (SEM) and chemical composition analysis (SEM-EDS) were performed to investigate the microstructure of the rivet material and to analyze the cracks. Results showed that the cause of rivet cracking is the accumulation and exceeding of critical tensile stresses in the rivet flange during the tube processing and the final riveting (forming) process. Moreover, it was discovered that rivet fracture is largely caused by structural defects (tertiary cementite Fe,Mn<sub>3</sub>C<sub>III</sub> along the boundaries of prior austenite grains) in the material resulting from the incorrectly selected parameters of the final heat treatment of the prefabricate (tube) from which the rivet was produced. The FEM simulation of the riveting and structural characterization results correlated well, so the rivet forming process and fracture mechanism could be fully investigated.https://www.mdpi.com/1996-1944/15/1/374metal formingrivetinglow-carbon steelFEM simulationmicrostructuretertiary cementite Fe<sub>3</sub>C<sub>III</sub> |
| spellingShingle | Jaroslaw Jan Jasinski Michal Tagowski FEM Simulation of the Riveting Process and Structural Analysis of Low-Carbon Steel Tubular Rivets Fracture Materials metal forming riveting low-carbon steel FEM simulation microstructure tertiary cementite Fe<sub>3</sub>C<sub>III</sub> |
| title | FEM Simulation of the Riveting Process and Structural Analysis of Low-Carbon Steel Tubular Rivets Fracture |
| title_full | FEM Simulation of the Riveting Process and Structural Analysis of Low-Carbon Steel Tubular Rivets Fracture |
| title_fullStr | FEM Simulation of the Riveting Process and Structural Analysis of Low-Carbon Steel Tubular Rivets Fracture |
| title_full_unstemmed | FEM Simulation of the Riveting Process and Structural Analysis of Low-Carbon Steel Tubular Rivets Fracture |
| title_short | FEM Simulation of the Riveting Process and Structural Analysis of Low-Carbon Steel Tubular Rivets Fracture |
| title_sort | fem simulation of the riveting process and structural analysis of low carbon steel tubular rivets fracture |
| topic | metal forming riveting low-carbon steel FEM simulation microstructure tertiary cementite Fe<sub>3</sub>C<sub>III</sub> |
| url | https://www.mdpi.com/1996-1944/15/1/374 |
| work_keys_str_mv | AT jaroslawjanjasinski femsimulationoftherivetingprocessandstructuralanalysisoflowcarbonsteeltubularrivetsfracture AT michaltagowski femsimulationoftherivetingprocessandstructuralanalysisoflowcarbonsteeltubularrivetsfracture |