Self-piercing riveting (SPR) is a mechanical joining process which is applied for joining similar and dissimilar lightweight materials in modern car body manufacturing. For qualifying SPR joints, cross sections must be investigated with respect to predefined quality features. Thus, numerous tests must be carried out in order to determine the maximum load capacity of SPR joints for different load angles. The growing number of materials used for the body-in-white requires a reliable and time efficient routine for predicting the joining behavior and the load capacity of SPR joints. In this study, the load capacity of three SPR joints was investigated numerically and experimentally using so-called KS2 samples. The results of axisymmetric two-dimensional finite element simulations (Hönsch et al in J Phys Conf Ser 1063:1-6, 2018) are the basis for three-dimensional simulations of the destructive testing procedure. The experimental setup of destructive testing was modeled using the FE software Simufact Forming 15. The numerically determined load capacity was validated with experimental data. Comparing the failure modes and the force–displacement curves revealed good agreement of simulations and experiments. Therefore, the presented simulation is a powerful tool for predicting the behavior of SPR joints under different load cases.

自冲铆接（SPR）是一种机械连接工艺，用于在现代车身制造中连接相似和不相似的轻质材料。对于合格的SPR接头，必须针对预定义的质量特征检查横截面。因此，为了确定不同负载角下的SPR接头的最大负载能力，必须进行大量测试。用于白车身的材料的数量不断增长，因此需要可靠且省时的例程来预测SPR接头的连接行为和负载能力。在这项研究中，使用所谓的KS2样本对三个SPR接头的承载能力进行了数值和实验研究。轴对称二维有限元模拟的结果（Hönsch等人，J Phys Conf Ser 1063：1-6，2018）是破坏性测试程序的三维模拟的基础。使用FE软件Simufact Forming 15对破坏性测试的实验设置进行建模。数字确定的负载能力已通过实验数据进行了验证。比较失效模式和力-位移曲线显示出模拟和实验的良好一致性。因此，所提出的仿真是预测不同载荷情况下SPR接头行为的有力工具。比较失效模式和力-位移曲线显示出仿真和实验的良好一致性。因此，所提出的仿真是预测不同载荷工况下SPR接头行为的有力工具。比较失效模式和力-位移曲线显示出模拟和实验的良好一致性。因此，所提出的仿真是预测不同载荷工况下SPR接头行为的有力工具。