Simulation-Based Design of Process Parameters for Human–Machine Collaborative Aircraft Assembly Riveting

In aircraft assembly, riveting is a critical joining method that directly determines structural integrity, fatigue life, and overall airframe reliability. With the increasing adoption of human–machine collaborative systems for complex assembly tasks, the rational design of riveting process parameters has become essential for ensuring consistent assembly quality. However, traditional experimental parameter optimization is time-consuming and costly, and lacks generalizability across varying working conditions. To address this challenge, this paper proposes a simulation-based design method for rapidly constructing process parameter schemes in human–machine collaborative aircraft assembly riveting. A theoretical dynamic model of the pneumatic reciprocating riveting gun is established to derive the relationship between input air pressure and piston impact velocity, providing physically grounded loading conditions for numerical simulation. A sequentially coupled numerical simulation method is developed using Ansys LS-DYNA and its Restart function to accurately model the entire multiple reciprocating impact forming process, which incorporating preloading analysis to reflect actual clamping conditions and reset analysis with applied damping to eliminate post-impact oscillations. Taking the riveting assembly of Aluminum (AL) 2024T351 rivets and AL 7039 aluminum sheets as a case study, the simulation successfully reproduces the rivet forming evolution over twelve consecutive impacts, revealing a two-stage deformation mechanism consisting of elastic springback and superimposed elastic-plastic deformation. Experimental verification on a self-built human–machine collaborative riveting platform demonstrates excellent agreement with simulation results in impact counts and upset head height. The proposed method provides a reliable, efficient, and low-cost approach for assembly process parameter calibration, offering direct theoretical support for assembly quality control, process robustness, and reliability assurance in aircraft manufacturing.