Self-Piercing Rivet (SPR) is a manufacturing process where two sheets (metals or polymer composites) are joined by a rivet. The rivet is simply pierced through both the sheets by applying a force ('setting force') which results in the formation of the joint. This is the key difference between SPR and conventional rivet, where a 'pre-hole' needs to be cut before inserting the rivet. SPR is increasingly used in the automotive industry to join parts made of dissimilar materials when processes are not feasible. When compared to other joining processes such as bolting, SPR introduces just one extra component (rivet), which reduces the weight of the joint. SPR also produces joints that are flush with the surface. This makes it the ideal joining candidate for relevant automotive applications. SPR can produce joints of significantly different qualities. The joints may be failed joints, with major defects. Successful joints can be characterized by several quality parameters. Some of these quality parameters are 'depth of penetration' of rivet, 'interlock' and 'remaining bottom thickness'. They influence the fatigue and shear strength of the joint. Hence, it is important to know the influence of the process parameters (like setting force) on the resulting joint quality. These parameters cannot be analytically predicted. However, they can be predicted by simulating the SPR process by FEM. In this thesis, the simulation of the SPR process is presented, which can help predict the variation of quality parameters versus the applied setting force.
