Validation of riveting process
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Validation of Riveting Validation of Riveting process process
Validation of Riveting Validation of Riveting process process
--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
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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
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– 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, GeorgiaInstitute of Technology.
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Problem Configuration
Top View of plates Rivet Close-up
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Top View of plates
Side View of specimen
Rivet Close-up
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Geometry
Punch
Rivet
Bottom Plate 2mm thick3.175
11
.9
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Bottom Plate 2mm thick
Top Plate 2mm thick
34.95.475
11
.9
14
.2
All Dimensions are in mm
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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(εtruem)
Isotropic hardening was considering during the simulation
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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, GeorgiaInstitute 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.
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Material definition contd..
4.00E+08
5.00E+08
6.00E+08
7.00E+08
Str
es
s (
Pa
)
Hardening curve 21174-T4 AL alloy
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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
Str
es
s (
Pa
)
Plastic Strain (mm/mm)
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Material definition contd..
6.00E+08
7.00E+08
8.00E+08
9.00E+08
1.00E+09
Str
es
s (
Pa
)
Hardening curve 2024-T3 AL alloy
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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
Str
es
s (
Pa
)
Plastic Strain (mm/mm)
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Boundary Conditions
Fix X direction displacement on rivet edge
Fix X direction displacement & apply displacement in Y direction to the puncher
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Fix Y direction displacement at plates side
Fix Y direction displacement at rivet head
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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
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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.
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RESULTS
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RESULTS
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UX Direction Displacement
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F = 26.9 KNDmax = 8.6454mm
F = 35.67 KNDmax = 9.6108mm
F = 45.02 KNDmax = 10.3766mm
F = 53.804 KNDmax = 10.9426mm
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UY Direction Displacement
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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
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Dmax Result Comparison
8.5
9
9.5
10
10.5
11
11.5
Dm
ax
(mm
)
Dmax Result Comparison
ANSYS
Exp
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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, GeorgiaInstitute of Technology.
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Final Protruding Height Comparison
3.5
4
4.5
5
5.5
6
Pro
tru
din
g H
eig
ht
(mm
)
Protruding Height (H) Comparison
ANSYS
Exp
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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, GeorgiaInstitute of Technology.
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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
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• 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
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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 andManufacturing, Wichita State University.