FEA modelling of setting and mechanical testing of aluminum blind rivets

This paper describes simulation of the setting of a blind rivet, using an axisymmetric model in the MSC.MARC/Mentat FEA package. A 6.4 mm diameter aluminium (5056 alloy) blind rivet was used to join two plates, each 4 mm thick. Initial material properties were used to simulate the H2 condition of the material after manufacture. Simulation of setting of the rivet was developed in the FE model. An optical profile projector was used to map the profile of the partially set and set rivet shapes. The FE model provided a good prediction of actual set shape. The forming forces involved in the setting of the blind rivet were also investigated. Actual rivets did not always set symmetrically. A relationship between setting force and the asymmetry of the set rivet was observed. The simulation of the pull test was based on BS EN ISO 14589:2001 [Blind rivets—mechanical testing]. FE models were developed to test the rivet to failure in tension using a 2D-axisymmetric model. Riveted joints were physically tested to failure in tension, using an uniaxial tensile testing machine with appropriate test jigs. The FE model results were compared with the physical test results.