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Experimental study on the effect of the riveting process on the bending resistance of beams composed of galvanized Q235 steel

  • Jingya Xue , Qing Wu , Xiaomiao Chen EMAIL logo , Shiliang Ma , Yunqing Wang , Jianbing Mo and Jianming Yang
Published/Copyright: December 31, 2024
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High Temperature Materials and Processes
From the journal High Temperature Materials and Processes Volume 43 Issue 1

Abstract

In this article, a hollow flange beam (ARHFB) composed of self-piercing rivet (SPR) and galvanized steel sheet was proposed, and the process parameters and mechanical properties of SPR connection technology for Q235 galvanized steel sheet were studied. Through the Taguchi method tests, the thickness of the joint section and the interlocking depth were measured. The tensile and shear tests were carried out, respectively, to obtain the corresponding quasi-static curves. In the four-point bending experiment of ARHFB, the effects of connection including welding, self-tapping screw, and SPR on the bending resistance of ARHFB were compared. The bearing capacity of ARHFB with self-tapping screws is significantly lower than that of welded ARHFB, and the 100 mm spacing SPR connection has strong substitutability for welding.

Keywords: self-piercing rivet; static performance; Taguchi method test; bearing capacity

1 Introduction

With the further development of the manufacturing industry in recent years, the connection technology with simple processes and a high degree of automation has been studied. Due to the existing technical level, it is impossible to manufacture integrated components, and the assembly between components used in construction production is inevitable [1,2]. At present, there are two kinds of bolt connection and welding in the traditional connection of light steel structures [3]. Bolt connection has high bearing capacity and deformation capacity, but the construction flexibility is poor and the degree of automation is low. The welding connection will produce large residual stress and stress concentration, which leads to the loss of bearing capacity and the reduction of fatigue strength. In addition, the welding connection requires high economic costs, and the reliability of the connection quality is relatively poor [4]. Therefore, as a cold-forming connection process, a self-piercing rivet (SPR) has been developed to replace the resistance welding process. The SPR connection process is a connection method with outstanding connection efficiency and reliability, which is often used in automobile manufacturing and aerospace fields. The SPR connection has the characteristics of high strength and can connect metal and non-metallic materials with different thicknesses.

A new type of assembled light steel structure is developed by combining light-weight and high-strength cold-formed steel with innovative technology. The installation is more convenient, the assembly efficiency is improved, and the service life of the building is prolonged. Therefore, building components connected by SPRs are studied. In 2018, Keerthan et al. [5,6,7] studied the rectangular hollow flange channel steel with rivet fastening by finite element simulation, which was considered a possible alternative to welded hollow flange channel steel (RHFCB). Subsequently, Siahaan et al. [8,9] carried out 15 bending tests to study the section bending moment capacity of riveted rectangular hollow flange channel beams and determine their ultimate bending moment bearing capacity.

To further optimize the use of cold-formed thin-walled materials, a hollow flange beam (ARHFB) with SPR connection is proposed, as shown in Figure 1. In this article, to explore the substitutability of rivet connection for traditional welding methods, a series of experimental studies have been carried out with rivet spacing as an important parameter index. Three different rivet spacings were set up in the test, including 100, 150, and 200 mm. The connection method of the test specimen also includes the use of traditional welding and self-tapping screw connection to compare and demonstrate the superiority of the SPR connection.

Figure 1 Section form and construction of ARHFBs.
Figure 1

Section form and construction of ARHFBs.

2 Technological process

The SPR process is an efficient cold-joining process, thus forming a mutually nested plastic deformation of the rivet connection process, known as SPR. There are two types of existing SPR equipment: EP-CTF and UARIO.

The SPR equipment used in this article is the latter, as shown in Figure 2(a). It is mainly composed of a power and control unit, a working clamp unit, a feeding unit, and a process control unit. Figure 2(b) is the cross-section diagram of the cold-forming SPR connection technology. Figure 2(c) is the working clamp unit, which is the main production part to produce riveting points. It is composed of a riveting punch and a riveting die. The riveting process is shown in Figure 3, including six stages: positioning, clamping, pressing, piercing, deformation, and forming. First, through the dynamic control unit, the riveting punch of the working clamp unit is controlled by manual displacement. Then, the rivet is sent to the riveting point by the feeding unit, and the rivet penetrates the upper plate through the pre-clamping stress and finally forms the riveting point of plastic deformation.

Figure 2 Self-piercing rivet connection equipment UARIO type: (a) self-piercing rivet equipment; (b) cross-section diagram; and (c) working clamp unit.
Figure 2

Self-piercing rivet connection equipment UARIO type: (a) self-piercing rivet equipment; (b) cross-section diagram; and (c) working clamp unit.

Figure 3 Riveting process. (a) Positioning, (b) clamping, (c) pressing, (d) piercing, (e) deforming, and (f) forming.
Figure 3

Riveting process. (a) Positioning, (b) clamping, (c) pressing, (d) piercing, (e) deforming, and (f) forming.

The efficiency of the SPR connection is 3–5 times that of the traditional self-tapping bolt connection in the past. Because the SPR process requires the current penetration of the upper plate, it is necessary to press the thick plate from the thin plate during riveting. The contact area of the riveting point is 5–7 times that of the thread, and the 100% inlay process makes it have greater friction [10]. This makes the riveting point have higher tensile and shear strength and higher dynamic fatigue strength after riveting forming. It also deepens the decision to combine the SPR connection with the light steel structure.

3 Testing materials

This section will specifically introduce the rivet model and steel model selected in the four-point bending test. A series of studies on the properties of rivets and steel were carried out. The rivet connection process was studied by the Taguchi method to ensure the reliability of the rivet connection process. The constitutive relation and material properties of steel are obtained by tensile test.

3.1 Material properties of steel

In the experimental study, Q235 steel with a thickness of 1.5 mm was selected. A total of eight specimens of C-shaped and U-shaped cold-formed thin-walled steel components with the same steel grade and two thicknesses of 1.5 and 2 mm were taken parallel to the rolling direction for the tensile test. In the tensile test, a 100 kN microcomputer-controlled electronic universal testing machine was used to obtain the constitutive relationship of steel (Figure 4). The material properties of steel are listed in Table 1.

Figure 4 Typical stress–strain for Q235 with 1.5 mm thickness.
Figure 4

Typical stress–strain for Q235 with 1.5 mm thickness.

Table 1

Key average material properties for Q235 steel from tensile coupon tests

Component type Steel thickness E f y f u ε y ε sh ε u ε f f u/f y
mm MPa MPa MPa % % % % –
U-shape 1.5 215,753 288.48 293.41 0.14 10.71 34.51 49.01 1.02
C-shape 1.5 200,922 277.23 287.58 0.14 10.57 35.68 50.01 1.04

Note: E – Young’s modulus, f y – yield strength, f u – ultimate strength, ε y – yield strain, ε sh – strain hardening strain, ε u – ultimate strain, ε f – strain at fracture.

3.2 Material properties of SPR

The process parameters of the rivet connection die affect the interlocking depth and riveting quality. To obtain the optimal process parameters, the die was selected by the Taguchi test. According to Section 3.1, the sample sheet combination selects a 1.5 mm thick U-shape Q235 galvanized steel plate and a 1.5 mm thick C-shape Q235 galvanized steel plate. Control factors were selected punch diameter, die depth, and bottom thickness values. The rivet Ø5.3 × 5.5 mm with surface electrogalvanized and passivated was selected. The universal testing machine CMT4304 is used to carry out the static load failure test of the riveting sample, and the test speed of the whole test is 10 mm·min−1. The tensile strength and shear strength failure tests were carried out, respectively. The failure state of the plate after the test is shown in Figure 5. The tensile strength and shear strength curves shown in Figures 6 and 7 are obtained.

Figure 5 The failure mode of the plates. (a) Tensile destructive test and (b) shear destructive test.
Figure 5

The failure mode of the plates. (a) Tensile destructive test and (b) shear destructive test.

Figure 6 Tensile load–displacement curve.
Figure 6

Tensile load–displacement curve.

Figure 7 Shear load–displacement curve.
Figure 7

Shear load–displacement curve.

The section view of the joint of the SPR connection is obtained by the wire-cutting process as shown in Figure 8. In addition, to facilitate the observation under the optical microscope to obtain a clear cross-sectional view and various parameter data, the locked riveted joint after cutting is inlaid, polished, and corroded. As can be seen from Figure 8, the outer diameter of the SPR connection point is Ø8.9 mm × 1.8 mm.

Figure 8 The cross-section diagram of the SPR connection point.
Figure 8

The cross-section diagram of the SPR connection point.

4 Four-point bending test and analysis

The ARHFB used in the test is assembled by two U-shaped components and two C-shaped components. Five rivet fastening ARHFBs with a span of 1,700 mm were tested for bending moment bearing capacity under a four-point bending arrangement. The four-point bending test was carried out using a 100 ton electro-hydraulic servo testing machine. The concentrated load is applied at 1/4 and 3/4 of the component. Therefore, five ARHFB specimens shown in Table 2 were designed. Table 2 lists the specimen labels and connection methods and records the results of the four-point bending test.

Table 2

Comparison of the experimental ultimate bending moment with different connecting methods

No. Connecting method Rivet spacing (mm) ARHFB sections d w × b f × d f0 – d f1 × t f × t w (mm) Test M u (kN·m)
1 Weld — 140 × 150 × 30 × 1.5 × 1.5 17.75
2 Self-tapping bolt 100 16.47
3 Self-piercing rivet 100 17.35
4 150 16.79
5 200 16.62

Note: d w – web depth, b f – flange width, d f0 – outer flange depth, d f1 – inner flange depth, t f – flange thickness, t w – web thickness.

The specimens were connected by three different connection methods, namely welding, self-tapping screw connection, and SPR connection. The SPR connection spacing is 100, 150, and 200 mm, respectively.

When the self-tapping screw is used as the connection method, the spacing of the self-tapping screws is 100 mm. According to the test results, the welded ARHFB has the highest bearing capacity. Among the self-tapping screw connection and SPR connection ARHFBs with a connection spacing of 100 mm, the SPR connection ARHFB has a higher bearing capacity, which is 5.3% higher than that of the self-tapping screw connection ARHFB. The bearing capacity of ARHFB with rivet spacing of 200 mm is still higher than that of ARHFB with self-tapping screw spacing of 100 mm by 0.9%. With the increase of the SPR connection spacing, the bearing capacity of ARHFB decreases. Compared with the welded ARHFB, the bearing capacity of the self-tapping screw-connected ARHFB is reduced by 7.8%, while the SPR-connected ARHFB with 100 mm spacing is only reduced by 2%. When the rivet spacing increases to 150 and 200 mm, the bearing capacity decreases by 5.7 and 6.8%, respectively, compared with the welded connection. Therefore, the SPR connection with 100 mm spacing can better replace the welding connection.

5 Conclusions

This article introduces the connection method of SPR and the type of rivet selected in detail. The application of rivet connection in ARHFB was also studied. The bearing capacity difference between the ARHFB connected by self-tapping screws and the ARHFB connected by self-piercing riveting is 5.3%. The results show that the SPR connection has better performance in the bending resistance of ARHFB than the traditional self-tapping screw connection. Since the difference between the load-carrying capacity of the ARHFB with a rivet spacing of 100 mm and the welded connection ARHFB is only 2%, the SPR connection with a rivet spacing of 100 mm can be used as an alternative to welding.

Acknowledgements

The research in this article was supported by the Instrumental Analysis Center of Jiangsu University of Science and Technology, Postgraduate Research & Practice Innovation Program of Jiangsu Province (SJCX23_2224), and the National Natural Science Foundation of China “Research on the interface behavior regulation mechanism of MPC-based coating/steel system in harsh marine environment” (52378265).

  1. Funding information: The research in this paper was supported by the Instrumental Analysis Center of Jiangsu University of Science and Technology, Postgraduate Research & Practice Innovation Program of Jiangsu Province (SJCX23_2224) and the National Natural Science Foundation of China “Research on the interface behavior regulation mechanism of MPC-based coating/steel system in harsh marine environment” (52378265).

  2. Author contributions: All authors have accepted responsibility for the entire content of this manuscript and consented to its submission to the journal, reviewed all the results and approved the final version of the manuscript. QW,SLM and XMC designed the experiments and JYX carried them out. YQW, JBM, JMY and JYX developed the model code and performed the simulations. JYX prepared the manuscript with contributions from all co-authors. Jingya Xue: Methodology, Software,Validation, Formal analysis, Investigation, Data Curation, Writing – Original Draft; Qing Wu: Resources, Writing – Review & Editing, Supervision, Project administration; Chen Xiaomiao: Writing – Review & Editing, Visualization, Supervision; Shiliang Ma: Resources, Project administration; Yunqing Wang: Methodology, Resources, Analysis; Jian bing Mo: Analysis; and Jianming Yang: Analysis.

  3. Conflict of interest: Authors state no conflict of interest.

  4. Data availability statement: The datasets generated during or analysed during the current study are available from the corresponding author on reasonable request.

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Received: 2024-03-31
Revised: 2024-06-04
Accepted: 2024-06-05
Published Online: 2024-12-31

© 2024 the author(s), published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/htmp-2024-0036
Keywords for this article
self-piercing rivet; static performance; Taguchi method test; bearing capacity
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  73. Microstructure and mechanical properties of submerged arc welded medium-thickness Q690qE high-strength steel plate joints
  74. Experimental study on the effect of the riveting process on the bending resistance of beams composed of galvanized Q235 steel
  75. Density functional theory study of Mg–Ho intermetallic phases
  76. Investigation of electrical properties and PTCR effect in double-donor doping BaTiO3 lead-free ceramics
  77. Special Issue on Thermal Management and Heat Transfer
  78. On the thermal performance of a three-dimensional cross-ternary hybrid nanofluid over a wedge using a Bayesian regularization neural network approach
  79. Time dependent model to analyze the magnetic refrigeration performance of gadolinium near the room temperature
  80. Heat transfer characteristics in a non-Newtonian (Williamson) hybrid nanofluid with Hall and convective boundary effects
  81. Computational role of homogeneous–heterogeneous chemical reactions and a mixed convective ternary hybrid nanofluid in a vertical porous microchannel
  82. Thermal conductivity evaluation of magnetized non-Newtonian nanofluid and dusty particles with thermal radiation
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