Xiong Feng, Yu Xuehou, Zhang Shuai, Wang Dengfeng, Xu Hongyu
Joint International Research Laboratory of Intelligent Manufacturing & Control of Key Parts for Energy-Efficient & New Energy Vehicles, Ministry of Education, Chongqing University of Technology, Chongqing 400054, China.
State Key Laboratory of Automotive Simulation and Control, Jilin University, Changchun 130022, China.
Materials (Basel). 2025 Mar 11;18(6):1233. doi: 10.3390/ma18061233.
Self-piercing riveting (SPR) has become a highly promising new method for connecting dissimilar materials in multi-material vehicle bodies, while the joint's forming quality which largely affects its connection performance lacks sufficient research. This study conducted a detailed numerical investigation on the forming quality of carbon-fiber-reinforced polymer (CFRP)/aluminum alloy (Al) SPR joint and proposed a novel multi-objective optimization strategy. First, the finite element (FE) model of CFRP/Al SPR joint forming was established and then verified to monitor the forming process. Second, based on FE numerical simulation, the action laws of rivet length and die structural parameters (die depth, die gap, and die radius) on the joint's forming quality indicators (bottom thickness and interlock value) were systematically studied to reveal the joint's forming characteristics. Finally, taking the rivet length and die structural parameters as design variables and the above forming quality indicators as optimization objectives, a hybrid Taguchi-Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method was proposed to conduct the multi-objective optimization of the joint's forming quality. According to the outcomes, the bottom thickness and interlock value of the joint were respectively increased by 10.18% and 34.17% compared with the baseline design, achieving a good multi-objective optimization of the joint's forming quality, which provides an effective new method for efficiently predicting and improving the forming quality of the CFRP/Al SPR joint.
自冲铆接（SPR）已成为在多材料车身中连接异种材料的一种极具前景的新方法，然而，对连接性能有很大影响的接头成形质量却缺乏充分研究。本研究对碳纤维增强聚合物（CFRP）/铝合金（Al）自冲铆接接头的成形质量进行了详细的数值研究，并提出了一种新颖的多目标优化策略。首先，建立了CFRP/Al自冲铆接接头成形的有限元（FE）模型，然后对其进行验证以监测成形过程。其次，基于有限元数值模拟，系统地研究了铆钉长度和模具结构参数（模具深度、模具间隙和模具半径）对接头成形质量指标（底部厚度和互锁值）的作用规律，以揭示接头的成形特性。最后，以铆钉长度和模具结构参数为设计变量，以上述成形质量指标为优化目标，提出了一种混合田口-理想解法排序技术（TOPSIS）方法，对接头的成形质量进行多目标优化。结果表明，与基线设计相比，接头的底部厚度和互锁值分别提高了10.18%和34.17%，实现了对接头成形质量的良好多目标优化，为高效预测和提高CFRP/Al自冲铆接接头的成形质量提供了一种有效的新方法。
