Burlakov I.A., Demetrashvili I.S., Kharitonov S.A. Influence of Blank Material Strength on Tool Stresses During Cold Heading of Rivets

DOI: 10.18503/1995-2732-2026-24-3-54-62

Abstract

Problem Statement (Relevance). The research is aimed at improving the durability of tooling for cold heading of rivets, which are widely used in the aerospace industry. High cyclic loads result in tooling failure, while the use of a composite tool with shroud carbide inserts requires optimization of its parameters, particularly the interference fit value, taking into account the properties of the material being headed. Objectives. The research is aimed at determining the effect of blank material strength on the stress state of a composite puncheon and developing a methodology for selecting an optimal interference fit. Methods Applied. Finite element modeling in QForm 11.2.400.3 has been used to investigate the cold heading of rivets made of six materials: KhN60VT nickel alloy, 12Kh18N10T stainless steel, M1 copper, and AD0, D16, and AMg5 aluminum alloys. Full-scale experiments on rivet heading have been conducted with recording of force parameters to validate the models. Originality. The principal novelty of the study is that heading softer aluminum alloys generates higher compressive stresses in the puncheon (up to 1300 MPa) than heading stronger materials such as steel or nickel alloy (up to 850 MPa). This has a beneficial effect on the service life of the carbide insert, which operates predominantly under compression. Based on the analytical model of thick-walled cylinders (Lamé's equations), a calculation methodology has been developed that relates the yield strengths of the rivet and tool materials, their properties, and geometry, making it possible to determine a range of optimal interference values that prevent both insert displacement and plastic deformation of the outer sleeve. Practical Relevance. The proposed engineering model makes it possible to account for the strength characteristics of a specific rivet material when designing tooling and selecting an optimal interference fit, thereby increasing tool life and process reliability.

Keywords

cold heading, rivet, composite tool, tool stresses, interference fit, rivet materials, modeling, carbide, QForm 11.2.400.3

For citation

Burlakov I.A., Demetrashvili I.S., Kharitonov S.A. Influence of Blank Material Strength on Tool Stresses During Cold Heading of Rivets. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2026, vol. 24, no. 3, pp. 54-62. https://doi.org/10.18503/1995-2732-2026-24-3-54-62

Igor A. Burlakov – PhD, Chief Specialist, Branch of JSC UEC Salut, Moscow, Russia Еmail: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID 0000-0002-9427-0217

Irina S. Demetrashvili – Process Engineer First Grade, Branch of JSC UEC NIID, Moscow, Russia. Email: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID 0009-0002-2363-0198

SergeyA. Kharitonov – Head of the Technology Bureau, Gorizont Machine-Building Design Bureau (Branch of JSC UEC Gorizont Machine-Building Design Bureau), Dzer-zhinsky, Russia Email: This email address is being protected from spambots. You need JavaScript enabled to view it.

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