Interference-fit riveting of slug rivet is a well-known enhanced joining technique for improving the fatigue life of aircraft structures significantly, and is widely used in aircraft thin-walled structures, where riveting interference which is controlled by process parameters is very important to the joining strength. This paper firstly analyzes the upsetting process of 2117-T4 aluminum slug rivet and divides it into two stages due to the deformation characteristics of rivet, the true strain of rivet header is composed by the strain in the shank upsetting stage and the strain in the header forming stage. Secondly, based on the above analysis, the power hardening rule is employed to establish the physics formula of pressing force, thereby derive the theoretical mathematic relationship between relative interference and riveting process parameters. Thirdly, a two-dimension axisymmetric model is used to simulate the upsetting process of slug rivet by Finite Element Method according to the rivet's features. Finally, compare the results calculated by the two mentioned methods above and analyze the effects of riveting process parameters on the riveting interference. It is shown that the theoretical method can be used for future analysis.
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