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<p>This study investigates the development and optimisation of a finite element model (FEM) for self-piercing riveting (SPR)–bonded hybrid joining, a technique that integrates the mechanical strength of SPR with the ductility provided by adhesive bonding. Key parameters influencing joint formation—such as the extendable die’s flap structure, extendable distance, and other die structural elements—were systematically analysed. A multi-objective genetic algorithm, in conjunction with a kriging surrogate model, was used to determine the optimal combination of die parameters, which were subsequently validated through comprehensive experimental procedures. The results revealed that increasing the number of flaps in the extendable die improved joint formation, with optimal interlock values observed at specific extendable distances. Additionally, the structural elements of the die were found to have a significant impact on the morphology of the joint. The kriging model, validated by FEM results, accurately predicted critical joint characteristics with minimal relative errors. The optimised die parameters led to notably enhancement in the hybrid joint’s performance, resulting in a 12.2% increase in interlock value, a 6.98% increase in bottom thickness, and a 3.90% increase in the residual thickness of the lower sheet. Experimental validation confirmed the FEM’s accuracy, demonstrating the hybrid joint’s combined advantages of SPR and adhesive bonding. These findings provide valuable insights into the optimisation of joint characteristics for advanced manufacturing processes, highlighting the effectiveness of integrating simulation and experimental approaches in engineering applications.</p>

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Optimization of extendable die SPR-bonded hybrid joining structures based on kriging and multi-objective genetic algorithms

  • 期刊论文

  • 发表日期：

    2025年7月21日

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  • Menghan Wang,
  • Shun Liu,
  • Hongrui Wu,
  • Yifeng Chen,
  • Yan Han

摘要

This study investigates the development and optimisation of a finite element model (FEM) for self-piercing riveting (SPR)–bonded hybrid joining, a technique that integrates the mechanical strength of SPR with the ductility provided by adhesive bonding. Key parameters influencing joint formation—such as the extendable die’s flap structure, extendable distance, and other die structural elements—were systematically analysed. A multi-objective genetic algorithm, in conjunction with a kriging surrogate model, was used to determine the optimal combination of die parameters, which were subsequently validated through comprehensive experimental procedures. The results revealed that increasing the number of flaps in the extendable die improved joint formation, with optimal interlock values observed at specific extendable distances. Additionally, the structural elements of the die were found to have a significant impact on the morphology of the joint. The kriging model, validated by FEM results, accurately predicted critical joint characteristics with minimal relative errors. The optimised die parameters led to notably enhancement in the hybrid joint’s performance, resulting in a 12.2% increase in interlock value, a 6.98% increase in bottom thickness, and a 3.90% increase in the residual thickness of the lower sheet. Experimental validation confirmed the FEM’s accuracy, demonstrating the hybrid joint’s combined advantages of SPR and adhesive bonding. These findings provide valuable insights into the optimisation of joint characteristics for advanced manufacturing processes, highlighting the effectiveness of integrating simulation and experimental approaches in engineering applications.