Abstract: The influence of process parameters on the fracture load of threaded hollow rivet joints remains insufficiently understood. To address this problem, this study employed a combined numerical and experimental approach. Numerical model of riveting and tensile processes of threaded hollow rivet was established, the mechanism of the sandwich thickness and the chamfer size on the morphology of the riveted joint was revealed, and the influence of sandwich thickness, chamfer size, and tensile rate on the fracture load of the riveted structure was clarified. The results indicate that the maximum fracture load of 1482 N is achieved under optimal parameters of sandwich thickness of 7.2 mm, chamfer size of 0.2 mm, and tensile speed of 3 mm/min. Variations in sandwich thickness alter the curvature radius of the joint interface, leading to contact gap formation. Meanwhile, mismatches between chamfer dimensions and material flow behavior induce chamfer gaps. The suppression of both contact gap and chamfer gap is identified as a critical factor in enhancing joint strength. Furthermore, high tensile speed promotes pronounced strain gradient, which is identified as the primary cause of reduced fracture load.