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Research on High Efficiency Numerical Simulation and Application of Steel-Aluminum Hybrid SPR Joint
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Ting Li, Ruidie Zhu, Zhigao He, Jiajie Shao, Mengqi Zhang
Automobile Technology & Material | 2026, (10) : 54 - 64
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Automobile Technology & Material | 2026, (10): 54-64
Research on High Efficiency Numerical Simulation and Application of Steel-Aluminum Hybrid SPR Joint
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Ting Li, Ruidie Zhu, Zhigao He, Jiajie Shao, Mengqi Zhang
Affiliations
  • BYD Auto Industry Co., Ltd., Shenzhen 518000
Published: 2026-10-20 doi: 10.19710/J.cnki.1003-8817.20260248
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To achieve accurate and efficient prediction of mechanical response and crash failure of steel‑aluminum hybrid self‑piercing riveted joints, and support the lightweight and crashworthiness design of steel‑aluminum hybrid vehicle bodies, adaptive mesh technology is adopted to establish an SPR forming simulation model for high‑strength steel and cast aluminum, and the influence law of process parameters on joint forming quality is analyzed. A refined solid model incorporating process history is constructed through residual stress‑strain field mapping, and the joint failure mechanism is revealed combined with mechanical tests. An efficient numerical simulation model for self‑piercing riveting (SPR) is developed and calibrated, and applied to the analysis of vehicle small‑overlap crash conditions. The results show that the error of characteristic cross‑sectional dimensions from forming simulation is no more than 10%; the peak load prediction error of the model considering process history is less than 6%, and that of the efficient SPR model is below 2%. Vehicle‑level simulation can accurately reproduce joint failure and structural deformation behaviors.

Self-piercing riveting  /  Mechanical response  /  Numerical simulation  /  Steel-aluminum hybrid material  /  Failure prediction
李婷, 朱瑞蝶, 何志高, 邵家杰, 张梦琪. 钢铝混合自冲铆接头高效数值仿真及应用研究. 汽车工艺与材料, 2026 , (10) : 54 -64 . DOI: 10.19710/J.cnki.1003-8817.20260248
Ting Li, Ruidie Zhu, Zhigao He, Jiajie Shao, Mengqi Zhang. Research on High Efficiency Numerical Simulation and Application of Steel-Aluminum Hybrid SPR Joint[J]. Automobile Technology & Material, 2026 , (10) : 54 -64 . DOI: 10.19710/J.cnki.1003-8817.20260248
Year 2026 volume Issue 10
59
8
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doi: 10.19710/J.cnki.1003-8817.20260248
  • Online Date:2026-10-29
  • Published:2026-10-20
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    BYD Auto Industry Co., Ltd., Shenzhen 518000
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表12种不同金属材料的力学参数
科
Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)
属
Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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