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Abstract: Self-piercing riveting (SPR) has become an interesting alternative joining technique for difficult to weld materials. A limitation of this technology is still the heavy experimental procedure needed for joint optimisation. In this paper, an experimental activity on Al6082-T4 sheet metal samples has been conducted to achieve a better understanding of the process. The joining process and the tensile tests have then been simulated using a FE code to predict deformed shape, failure mechanism (e.g. crack propagation, rivet pull-out) and shear resistance of the joint. Results show how this procedure can be a powerful tool for joint optimisation. [Copyright &y& Elsevier]