How to Remove Self Piercing Rivets?
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Table of Contents
Do you know how to remove self piercing rivets? Let us explore it.
Table of Contents
Why Remove Self Piercing Rivets?
You may have a need to remove self piercing rivets when your product has been manufactured incorrectly and parts need to be replaced; when the product needs to be repaired or upgraded after use; or when the material needs to be separated during the recycling process.
- Industrial Defect Repair
- Design Change Adaptation
- Automotive Collision Repair
- Functional Upgrades
- Rivet Reuse
3 Ways to Remove Self Piercing Rivets
The method of removing self piercing rivets varies depending on the applicable scenario. Below is a brief comparison of the three main removal methods.
| Assessment dimensions | drilling method | Angle grinder cutting method | Hydraulic shovel dismantling method |
| Applicable | General maintenance | Emergency/no power environment | High Volume Professional Rework |
| Efficiency | 5-8 minutes/point | 10-15 minutes/point | 2-3 seconds/point |
| Risk of substrate damage | Low (controlled drilling depth) | Medium (thermal effects of cutting) | Extremely low (precise mold matching) |
| equipment cost | €200-500 (electric drill + drill) | €150-300 (angle grinder) | €8,000-15,000 (hydraulic systems) |
| Skill Requirements | Medium (drilling accuracy required) | High (experience in cutting operations) | Professional training (parameterization) |
Method 1: Borehole method (recommended general program)
The drilling method is generally suitable for removing standard hardness spr rivets. if you are removing spr on aluminum, steel, composites (non-brittle substrates), such as automotive body repairs, aerospace structural rebuilds, then the drilling method is a very applicable and economical method.
advance preparation
| Tools/Parameters | Specification Requirements |
| Drill | Brushless motor with adjustable speed (1,500-3,000 RPM), e.g. Bosch GSR 18V-EC |
| Driller | HSS or carbide drill bit, diameter = rivet head diameter x 0.8 (Example: 4mm drill bit for 5mm rivet) |
| Coolant | Water-based cutting fluid (aluminum) or oil-based coolant (steel), flow rate ≥50ml/min |
| Positioning Tools | Center punch (hardness ≥ 60 HRC), punch point depth ≤ 0.5mm |
Procedures
- Positioning and punching point: Use the center punch to make a concave point in the center of the rivet head to prevent the drill bit from slipping. Punch point offset ≤ 0.1mm to avoid drilling eccentricity.
- Drill penetration: Aluminum: 3,000 RPM, feed rate 0.1mm/rev. Steel 1,500 RPM, feed rate 0.05mm/rev. Back off every 2mm of drilling and blow off debris with compressed air.
- Removal of residues: drill until the head of the rivet is disengaged, tap the bottom with a flat head punch to eject the locking structure. Place a 0.5mm copper pad between the punch and the substrate to prevent surface scratches.
Method 2: Angle grinder cutting method (high strength rivets)
If you want to remove high-strength spr rivets made of boron steel, or if the removal environment doesn’t have a way to operate on the opposite side, then the angle grinder cutting method is the best removal solution. Operators choose this method when field equipment is being repaired or when there is no power.
advance preparation
| Tools/Parameters | Specification Requirements |
| Angle Grinding Machine | 10,000 RPM, 110mm cutting blade, e.g. Makita GA9020 |
| Cutting Blade | Diamond or Aluminum Oxide Cutting Blades 1mm Thick (Grit 80#) |
| Crowbar | Titanium one screwdriver (hardness ≥45 HRC), blade thickness 0.8mm |
Procedures
- Head cutting: Adjust the angle between the angle grinder and the workpiece to 15°, cut along the outer edge of the head of the rivet, depth to the surface of the substrate. Cutting speed 2-3mm/s, avoid overheating (aluminum temperature <150°C).
- Pry off the head: Insert a screwdriver into the cutting seam and slowly pry up the rivet head at an angle of 30°.
- Ejecting the stem: Eject the residual part by striking vertically with a punch (diameter = rivet stem x 0.9) from the reverse side of the base material. Spray WD-40 to reduce friction and lower ejection force (≥50%).
Method 3: Hydraulic shovel demolition (professional level)
Hydraulic shovel removal is a professional and efficient method of removing self piercing rivets. It is mainly used to remove a large number of self piercing rivets of the same size, such as automobile production line rework. Engineers choose to apply the Hydraulic Shovel Removal Method for rapid dismantling of body-in-white SPR stations and maintenance of aerospace structural components.
advance preparation
| Tools/Parameters | Specification |
| Hydraulic Shovel | Böllhoff RIVSET® dismantling module, pressure range 10-50kN |
| Mold Adaptation | Removal mold groove diameter = rivet head diameter + 0.1mm (example: 5.1mm mold for 5mm rivet) |
| Pressure Setting | Aluminum: 15-20kN, steel: 25-30kN (dynamically adjusted according to the thickness of the substrate) |
Procedures
- Mold Installation: Select a removal mold that matches the rivet to ensure precise alignment of the recess with the rivet head. Verify the position of the mold using a laser alignment gauge (accuracy ±0.05mm).
- Reverse Punching: Start the hydraulic system, the punch impacts the rivet head with set pressure to destroy the locking structure.
- Residue cleaning: Use magnetic suction bar to collect the dislodged rivets and check the integrity of the substrate holes (hole enlargement ≤ 0.3mm).
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By reading this guide, I’m sure you have a good idea of what tools should be used to remove self piercing rivets in different situations. You have become a qualified technician’s.
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