Improving the Robustness of Numerical Simulation Approach by Including Process Results 2020-28-0375
Riveting is a permanent fastening process used in the automotive
industry. In transmission components like flywheel & clutch
assemblies, it plays an integral role in fastening the sheet
metals. Residual stresses of any kind can lead to dimensional and
structural instability. Now a general practice among numerical
analysts is to carry out the simulation using standard CAD model.
They often neglect the changes in dimensions and residual stresses
developed in the part. Such approach does not take into account the
real world scenario. This could result in over or under estimation
of the product by numerical simulation. Hence, it has become a
necessity for the analysts to find ways to have a robust approach.
The solution we present is to compute crushing of rivet at nominal
dimensions/hardness, map the residual stresses of crushed rivet in
the standard computational software and simulate it for the
assembly loading conditions. This approach augments our FEA
simulations to simulate actual conditions and produce a robust
design. This can be further extended to products involving
mechanical joining processes. Keywords: Rivet crushing, process
mapping, residual stress,bstrain hardening.