article published yes Fabian Kappe author 66459 Mathias Bobbert author 7850 Gerson Meschut author 320560000-0002-2763-1246 43 department 157 department TRR 285: Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen Prozessketten project TRR 285 - Project Area C project TRR 285 - Subproject C02 project Climate change has led to a large number of countries deciding to reduce carbon dioxide (CO<jats:sub>2</jats:sub>) emissions significantly. As the mobility sector is a major contributor to CO<jats:sub>2</jats:sub>, various strategies are being pursued to achieve the climate targets set. An increasingly applied lightweight design method is the use of multi-material constructions. To join these structures, mechanical joining technologies such as self-pierce riveting are being used. As a result of the currently rigid tool systems, which cannot react to changing boundary conditions, a large number of rivet–die combinations is required to join the rising number of materials as well as material thickness combinations. Thus, new, versatile joining technologies are needed that can react to the described changes. The versatile self-piercing riveting (V-SPR) process is one possible approach. In this process, different material thicknesses can be joined by using a multi-range capable rivet which is set by a joining system with extended actuator technology. In this study, the V-SPR joining process is analysed numerically according to the influence of the geometrical rivet parameters on the joints characteristics as well as the resulting material flow. The investigations showed that the shank geometry has a decisive influence on the expansion of the rivet. Furthermore, the rivet length could be proven to be an influencing factor. By changing the head radii and the protrusion height, the forming behaviour of the rivet head onto the punch-sided joining part could be improved and thus the formation of air pockets was prevented. Based on the numerical investigations, a novel rivet geometry was developed and produced by machining. Subsequently, experimentally produced joints were analysed according to their joint formation and load-bearing capacity. SAGE Publications2024 eng 0954-4089 2041-300910.1177/09544089241263141 Kappe, F., Bobbert, M., &#38; Meschut, G. (2024). Investigation of the influence of the rivet geometry on joint formation for a versatile self-piercing riveting process. <i>Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering</i>, Article 09544089241263141. <a href="https://doi.org/10.1177/09544089241263141">https://doi.org/10.1177/09544089241263141</a> F. Kappe, M. Bobbert, and G. Meschut, “Investigation of the influence of the rivet geometry on joint formation for a versatile self-piercing riveting process,” <i>Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering</i>, Art. no. 09544089241263141, 2024, doi: <a href="https://doi.org/10.1177/09544089241263141">10.1177/09544089241263141</a>. F. Kappe, M. Bobbert, G. Meschut, Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering (2024). Kappe, Fabian, Mathias Bobbert, and Gerson Meschut. “Investigation of the Influence of the Rivet Geometry on Joint Formation for a Versatile Self-Piercing Riveting Process.” <i>Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering</i>, 2024. <a href="https://doi.org/10.1177/09544089241263141">https://doi.org/10.1177/09544089241263141</a>. Kappe, Fabian, et al. “Investigation of the Influence of the Rivet Geometry on Joint Formation for a Versatile Self-Piercing Riveting Process.” <i>Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering</i>, 09544089241263141, SAGE Publications, 2024, doi:<a href="https://doi.org/10.1177/09544089241263141">10.1177/09544089241263141</a>. Kappe F, Bobbert M, Meschut G. Investigation of the influence of the rivet geometry on joint formation for a versatile self-piercing riveting process. <i>Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering</i>. Published online 2024. doi:<a href="https://doi.org/10.1177/09544089241263141">10.1177/09544089241263141</a> @article{Kappe_Bobbert_Meschut_2024, title={Investigation of the influence of the rivet geometry on joint formation for a versatile self-piercing riveting process}, DOI={<a href="https://doi.org/10.1177/09544089241263141">10.1177/09544089241263141</a>}, number={09544089241263141}, journal={Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering}, publisher={SAGE Publications}, author={Kappe, Fabian and Bobbert, Mathias and Meschut, Gerson}, year={2024} } 614132025-09-23T13:06:35Z2025-09-23T13:15:51Z