Abstract
This paper investigates the effects of die design geometrical parameters on self-piercing riveting (SPR) operations and the joint quality of 5052 aluminum alloy. Piped-die types with various designed diameters and depths were prepared. Subsequently, a 2D axisymmetric simulation model was developed to analyze the riveting efficiency and forming mechanism of SPR joints. The forming quality of specimens was studied by evaluating the cross-sections of joints obtained from the 2D simulation model and experiments. The mechanical properties of the specimens were analyzed by comparing the maximum shear load and energy absorption. The results indicate that a larger die diameter results in better rivet flaring, forming quality and mechanical properties of the specimens. Additionally, the forming quality improves with an increase in die depth, while the mechanical properties initially decrease and then increase. A smaller die depth benefits rivet flaring but affects the rivet penetration process. The maximum interlock value of 0.28 mm was recorded for the specimen obtained using a die with a depth of 1.25 mm; however, the forming quality deteriorated due to a large head height of 0.37 mm.