An elastic-plastic model for accurately predicting the riveting force and deformation of pressure riveting aluminum alloy

Abstract Accurate prediction of riveting force is essential for process optimization as it critically determines riveting quality. This study develops a riveting force prediction model based on elastic-plastic mechanics and the exponential hardening criterion, focusing on clarifying the correlation between riveting force and deformation behavior. The model innovatively divides the rivet driven head into easy-deformation and difficult-deformation zones, and integrates block analysis, overall analysis, and height coefficients to enhance predictive accuracy. For rivets with diameters ≤4 mm, the model achieves precise riveting force prediction; for those with diameters >4 mm, it effectively defines the reasonable range of riveting force values. To validate the model, a three-dimensional isotropic finite element simulation model is constructed to simulate radial and longitudinal deformation of rivets, while riveting tests are conducted on specimens of different specifications. Experimental results confirm the model’s high accuracy: the error between predicted and measured riveting force is 1.7% for 4 mm diameter rivets, and the errors of maximum riveting force predictions are 2.9% and 6.8% for 5 mm and 6 mm diameter rivets, respectively. Further verification shows that the model can effectively control riveting interference within the optimal range, providing a reliable theoretical basis for optimizing practical riveting processes.