Validation of riveting process
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Transcript of Validation of riveting process
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
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.
Problem Configuration
Top View of plates Rivet Close-up
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Top View of plates
Side View of specimen
Rivet Close-up
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
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.
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)
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)
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
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.
RESULTS
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RESULTS
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
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
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.
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.
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
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.