Forming law and mechanical property of carbon fibre reinforced plastics and aluminum alloy self-piercing riveted joint
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摘要: 碳纤维复合材料在轻量化车身制造方面具有巨大的潜力和应用空间，而实现复合材料的有效连接则为一大挑战。采用自冲铆技术开展碳纤维复合材料和铝合金板材的连接工艺探索，总结了铆钉类型、冲铆速度和铆模尺寸对接头结构参数的影响规律，分析了冲铆过程中底切结构的形成机制，考察了不同板厚接头的强度性能及失效方式。研究发现，自冲铆接头底切值主要受到钉脚刺入下板深度及脚尖局部力矩作用的影响，且随铆钉有效长度、冲铆速度及铆模深度的提升而增加。通过工艺优化，碳纤维复合材料和铝合金板之间可得到成形结构良好的自冲铆接头，其机械内锁强度能够达到铝合金板接头的89%，而相同板厚时，复合材料自冲铆接头相比于铝合金接头的突出薄弱点在于其上板抵抗集中应力破坏的能力。Abstract: There are great potential and application space of carbon fibre reinforced plastics (CFRP) in lightweight vehicle body manufacturing, and realizing effective connection of the material is still a great challenge. The connection process between CFRP and aluminum alloy plate was explored using self-piercing riveting (SPR) technology, and the effects of rivet type, punching speed and riveting die dimension on joint structural parameters were summarized, then the forming mechanism of undercut structure in the riveting process was analyzed, the strength performance and failure mode of joints with various plate thicknesses were also investigated. It is found that the undercut value of SPR joint is affected by both the penetration depth of the rivet shank into the lower plate and the local moment on the rivet toe, and increases with the rise of the effective rivet length, the punching speed and the depth of the die. Through process optimization, SPR joints between CFRP and aluminum plates with good forming structure can be obtained, and the mechanical internal locking strength can reach 89% of that of aluminum alloy plates joint. However, compared with aluminum alloy joint with the same plate thickness, the outstanding weakness of CFRP joint is the ability of its CFRP upper plate to resist concentrated stress damage.
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图 2 典型自冲铆铆钉(a)和铆模(b)结构示意图
Figure 2. Typical section structure of the rivet (a) and die (b) of SPR
图 4 试验板材结构及性能：(a)碳纤维增强体结构；(b)拉伸应力-应变曲线
Figure 4. Structure and performance of test plates: (a) Structure of carbon fiber reinforcement; (b) Tensile stress-strain curves
图 5 自冲铆接头拉伸剪切试样
CFRP—Carbon fiber reinforced plastics; dc—Plate thickness
Figure 5. Tensile shear sample of SPR joint
图 6 铆钉长度和硬度对CFRP-Al板自冲铆接头结构影响
Figure 6. Influence of rivet length and hardness on CFRP-Al plates SPR joint structure
图 7 不同铆钉的CFRP-Al板自冲铆接头结构
Figure 7. CFRP-Al plates SPR joint structures with various rivets
图 8 冲铆速度对CFRP-Al板自冲铆接头结构的影响
Figure 8. Influence of punching speed on CFRP-Al plates SPR joint structure
图 9 冲铆速度V对CFRP-Al板自冲铆接头铆钉溃缩的影响
Figure 9. Influence of punching speed V on rivet collapse of CFRP-Al plates SPR joint
图 10 铆模尺寸对CFRP-Al板自冲铆接头结构的影响
Figure 10. Influence of die dimensions on CFRP-Al plates SPR joint structure
图 11 刺穿CFRP和铝合金上板后钉脚扩展状态：(a) 2 mm-2 mm CFRP-Al板接头，V=50 mm·s−1；(b) 2 mm-2 mm Al-Al板接头，V=140 mm·s−1
Figure 11. Rivet flaring state after piercing the CFRP and Al upper plate: (a) 2 mm-2 mm CFRP-Al joint, V=50 mm·s−1; (b) 2 mm-2 mm Al-Al joint, V=140 mm·s−1
图 12 冲铆过程钉脚受力示意图：(a)未张开钉脚；(b)张开钉脚
Figure 12. Schematic diagram of force on rivet shank during punching process: (a) Rivet shank not flared; (b) Rivet shank flared
图 14 不同冲铆速度下CFRP-Al板自冲铆接头结构
Figure 14. CFRP-Al plates SPR joint structures under various punching speeds
图 15 CFRP-Al板自冲铆接头结构参数随冲铆速度的变化过程：(a)刺入深度Ls和底切值；(b)钉脚张开值和钉头余高
Figure 15. Changing process of CFRP-Al plates SPR joint structural parameters with punching speed: (a) Penetration depth Ls and undercut; (b) Flare dimension and head height
图 16 不同上板材料及厚度的自冲铆接头结构对比
Figure 16. Structural comparison of SPR joints with various upper plate materials and thicknesses
图 17 不同上板材料及厚度的自冲铆接头载荷-位移曲线
Figure 17. Load-displacement curves of SPR joints with various upper plate materials and thicknesses
图 18 不同上板材料及厚度的自冲铆接头失效破坏形貌
Figure 18. Failure morphologies of SPR joints with various upper plate materials and thicknesses
图 19 塑性材料和脆性材料承受集中应力示意图：(a)受集中应力情况；(b)塑性材料对集中应力的分散；(c)脆性材料受集中应力破坏
Figure 19. Schematic diagram of plastic and brittle materials bearing concentrated stress: (a) Bearing concentrated stress; (b) Dispersion of concentrated stress by plastic materials; (c) Failure of brittle materials under concentrated stress
表 1 部分对比试验编号及工艺参数设定
Table 1. Partial comparative test number and process parameter setting
Number dc/mm L/mm Rivet hardness (HV) Punching speed V/(mm·s−1) rm/mm dm/mm 1 1 5 410 225 10 2.0 2 2 5.5 410 225 10 2.0 3 2 6 410 225 10 2.0 4 2 6.5 410 225 10 2.0 5 2 6.5 290 225 10 2.0 6 2 6.5 480 225 10 2.0 7 3 7.5 410 225 10 2.0 8 3 7.5 410 265 10 2.0 9 3 7.5 410 300 10 2.0 10 3 7.5 410 325 10 2.0 11 3 7.5 480 300 9 1.8 12 3 7.5 480 300 10 2.0 13 3 7.5 480 300 9 2.0 14 3 7.5 480 300 9 2.2 15 2 6 480 225 10 2.0 16* 2 6 410 225 10 2.0 Note: Number 16* is the Al-Al plate SPR connection test. 
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