Browse Publications Technical Papers 2020-28-0375
2020-09-25

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.

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