Numerical analysis of residual stress distribution in riveted lap joint under tension

Riveted joints are a common location of fatigue cracks in aircraft metal structures. Fatigue life of such joints as well as a place of cracks nucleation is strongly influence by a stress distribution in sheets, which is a result of residual stresses (mainly after riveting) and stresses induced by external loads. Stress distribution in two-row lap joint was investigated with the use of Finite Element Method. The joint consist of two 1.5 mm sheets and two protruding rivets with diameter equal to 4 mm, made of 2024 T3 (sheets) and 2117 T4 (rivets) aluminium alloys. The simulations covered a riveting process and tensile stages. The 3D models of joint with the universal rivets and with the brazier, rivets with a compensator were prepared. Elastoplastic material properties as well as geometric nonlinearity and contact phenomena were included. The results of simulations show that the residual stress distribution after release of tensile loading varies significantly from the distribution after riveting only. This fact should therefore be taken into account in a fatigue life estimation of such joints performed based on a FE calculation. The paper presents also the influence of the analysed rivet geometry on the stress distribution at the sheets faying surfaces.