Investigation of the strength of forged rivet joints made with different bucking bar gaps

The purpose of this study is to examine the effect of the rivet heads formed on the rivet strength by an experimental study if the bucking bar used in the forged rivet application includes gaps with different angles.

0.81 (0.032”) mm thick 2024 T3 sheets were used for the rivet joints. AD 2117 T4 forged rivets with a diameter of 3.2 mm (0.125″, 1/8″) are used for the joints. The special bucking bars (sidewall intersection angles of flat, 40°, 60° and 80°) were manufactured for the riveting process. To determine the mechanical properties of the prepared samples, cross-tension and tensile-shear tests were performed on a universal tensile testing machine.

As a result of the tensile-shear tests and cross-tensile, use of an 80 degrees bucking bar instead of rivets with a flat bucking bar increases the strength of the joint by approximately 20%. There is no systematic change in elongation. The results of tensile-shear and cross-tensile tests showed that forging rivets by special bucking bars have a significant effect on joint strength.

Increase in strength will require the use of thinner sheet metal and smaller rivets to achieve the same strength. This will reduce the weight of the aircraft. Weight reduction also means less fuel consumption and more economical flight. This increase in strength is a very important scientific achievement.