The increasing demands of energy efficiency and lightweight construction in automobile industry led to development of sheet material joining techniques such as self piercing riveting, mechanical clinching. The body in white of vehicle on an average account for about 25-30% of total vehicle weight. Thus, a mixture of lightweight materials like aluminum and high strength steel is increasingly used in automobile applications. In a structure, joint is considered to be the weakest part, so it should be strong enough to hold both the sheets together during the crash loadings. In this work process simulation of self piercing riveted joint of aluminum sheets (A6060 T4) is validated with the help of FEA software. Parametrical study is performed to get best possible results with good mechanical interlock of two aluminum sheets.
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