---
_id: '65373'
abstract:
- lang: eng
  text: To reduce CO₂ emissions, the automotive industry is adopting multi-material
    structures. Fusion-based joining reaches its limits for aluminium–steel due to
    brittle intermetallic phases and mismatched thermophysical properties; therefore,
    mechanical joining (e.g., SPR) is used. Though conventional SPR requires tool
    changes for different stack-ups. Versatile self-piercing riveting (V-SPR) addresses
    this with an extended punch actuator and a multi-range-capable rivet (Kappe in
    PERD16:363–378, 2022), enabling joints up to 600 MPa across varying thicknesses
    without retooling. With the use of ultra-high-strength steels up to 1000 MPa,
    optimisation is required. This study quantifies how rivet shank geometry affects
    joint formation using a design of experiments and validated 2D axisymmetric FE
    simulations. The optimum depends strongly on the material system. For CP1000–EN
    AW-6014, maximum interlock f is predicted for a medium shank thickness of about
    0.73 mm, a small internal foot radius of 0.620 mm, and a deeper drill depth of
    3.136 mm, yielding f fc =0.4503 mm with a desirability of 0.954. For EN AW-6014–EN
    AW-6014, the optimum shifts to a thinner shank of 0.670 mm, a larger internal
    foot radius of 0.820 mm and a shallow drill depth of 2.30 mm, giving ffc = 0.3023
    mm with a desirability of 1.0. A compromise geometry of 0.713 mm shank thickness,
    0.776 mm internal foot radius and 2.755 mm drill depth achieves ffc = 0.3641 mm
    for CP1000–aluminium and ffc = 0.1851 mm for aluminium–aluminium with an overall
    desirability D = 0.6378, expanding V-SPR to ultra-high-strength steel–aluminium
    joints while maintaining aluminium joinability.
article_number: '43'
author:
- first_name: Pia Katharina
  full_name: Kaimann, Pia Katharina
  id: '44935'
  last_name: Kaimann
- first_name: Nico
  full_name: Ritter, Nico
  last_name: Ritter
- first_name: Mathias
  full_name: Bobbert, Mathias
  id: '7850'
  last_name: Bobbert
- first_name: Gerson
  full_name: Meschut, Gerson
  id: '32056'
  last_name: Meschut
  orcid: 0000-0002-2763-1246
citation:
  ama: Kaimann PK, Ritter N, Bobbert M, Meschut G. Influence of the shank geometry
    on the joint formation of the versatile self-piercing riveting of ultra-high-strength
    steel-aluminium and aluminium-aluminium assemblies. <i>Discover Mechanical Engineering</i>.
    2026;5(1). doi:<a href="https://doi.org/10.1007/s44245-026-00221-y">10.1007/s44245-026-00221-y</a>
  apa: Kaimann, P. K., Ritter, N., Bobbert, M., &#38; Meschut, G. (2026). Influence
    of the shank geometry on the joint formation of the versatile self-piercing riveting
    of ultra-high-strength steel-aluminium and aluminium-aluminium assemblies. <i>Discover
    Mechanical Engineering</i>, <i>5</i>(1), Article 43. <a href="https://doi.org/10.1007/s44245-026-00221-y">https://doi.org/10.1007/s44245-026-00221-y</a>
  bibtex: '@article{Kaimann_Ritter_Bobbert_Meschut_2026, title={Influence of the shank
    geometry on the joint formation of the versatile self-piercing riveting of ultra-high-strength
    steel-aluminium and aluminium-aluminium assemblies}, volume={5}, DOI={<a href="https://doi.org/10.1007/s44245-026-00221-y">10.1007/s44245-026-00221-y</a>},
    number={143}, journal={Discover Mechanical Engineering}, publisher={Springer Science
    and Business Media LLC}, author={Kaimann, Pia Katharina and Ritter, Nico and Bobbert,
    Mathias and Meschut, Gerson}, year={2026} }'
  chicago: Kaimann, Pia Katharina, Nico Ritter, Mathias Bobbert, and Gerson Meschut.
    “Influence of the Shank Geometry on the Joint Formation of the Versatile Self-Piercing
    Riveting of Ultra-High-Strength Steel-Aluminium and Aluminium-Aluminium Assemblies.”
    <i>Discover Mechanical Engineering</i> 5, no. 1 (2026). <a href="https://doi.org/10.1007/s44245-026-00221-y">https://doi.org/10.1007/s44245-026-00221-y</a>.
  ieee: 'P. K. Kaimann, N. Ritter, M. Bobbert, and G. Meschut, “Influence of the shank
    geometry on the joint formation of the versatile self-piercing riveting of ultra-high-strength
    steel-aluminium and aluminium-aluminium assemblies,” <i>Discover Mechanical Engineering</i>,
    vol. 5, no. 1, Art. no. 43, 2026, doi: <a href="https://doi.org/10.1007/s44245-026-00221-y">10.1007/s44245-026-00221-y</a>.'
  mla: Kaimann, Pia Katharina, et al. “Influence of the Shank Geometry on the Joint
    Formation of the Versatile Self-Piercing Riveting of Ultra-High-Strength Steel-Aluminium
    and Aluminium-Aluminium Assemblies.” <i>Discover Mechanical Engineering</i>, vol.
    5, no. 1, 43, Springer Science and Business Media LLC, 2026, doi:<a href="https://doi.org/10.1007/s44245-026-00221-y">10.1007/s44245-026-00221-y</a>.
  short: P.K. Kaimann, N. Ritter, M. Bobbert, G. Meschut, Discover Mechanical Engineering
    5 (2026).
date_created: 2026-04-08T08:25:32Z
date_updated: 2026-04-08T08:34:40Z
department:
- _id: '43'
- _id: '157'
doi: 10.1007/s44245-026-00221-y
intvolume: '         5'
issue: '1'
language:
- iso: eng
project:
- _id: '130'
  name: 'TRR 285:  Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen
    Prozessketten'
- _id: '133'
  name: TRR 285 - Project Area C
- _id: '146'
  name: TRR 285 - Subproject C02
publication: Discover Mechanical Engineering
publication_identifier:
  issn:
  - 2731-6564
publication_status: published
publisher: Springer Science and Business Media LLC
quality_controlled: '1'
status: public
title: Influence of the shank geometry on the joint formation of the versatile self-piercing
  riveting of ultra-high-strength steel-aluminium and aluminium-aluminium assemblies
type: journal_article
user_id: '44935'
volume: 5
year: '2026'
...