Study of the Friction Forge Riveting (FFR) Process and Numerical Simulation

In the aim to set up a robotized assembly process, this article studies the feasibility of Friction Forge Riveting (FFR) for industrial application as it can be considered as a good alternative for reinforcing multi-material assemblies. A finite element study is developed using Abaqus® and it enables the deformation of a cylindrical bar into the shape of a rivet by friction. The sensibility of the assembly parameters is taken into account in this study. A thermomechanical axisymmetric model for an aluminum rivet formed by a tungsten-lanthanum tool is proposed. A remeshing algorithm developed using Python is used in the simulation because of the large strain induced during the process. The simulation of the thermomechanical behavior of the rivet is important for the improvement of this innovative process. Experimental studies were developed in a CNC machine and the force and temperature data is compared with the simulation.