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Mechanical Joining Technology in modern Vehicles' Material Mix
Wolfgang ObermannDirector Marketing Systems
Emhart Teknologies
2
Overview
Car body joining technologies
Modular equipment design
Self Piercing Riveting (SPR)
semi-hollow rivet
solid punch rivet
Clinching
Blind riveting
3
Mechanical Joining - Characteristics Self Piercing Riveting (SPR)
Joining technology for many materials (thin sheet, high strength sheet metal, Aluminium)Substitutes spot weldingNo pre-punchingVery high joint strengthComposite design possible2 or more layers can be rivetedSelf piercing riveting in combination with glue can beeffectedCold joining technology
4
Three Technologies in One System
Self Piercing Riveting (SPR)
Self Piercing Rivet Solid Punch Rivet
Clinching
Joining element Forming
Front lid / tailgate
RoofDoorsCar bodyUnder body
Visual area
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Shear Test Comparison of Joining Methods
0
1
2
3
4
5
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0 1 2 3 4 5 6 7elongation (mm)
forc
e (k
N)
Stanznieten Ø5,3x5 H4 Vollnieten Ø5x4,2 ES Clinchen
Scherzugvergleich der Fügeverfahren Stanznieten, Vollnieten und Clinchen
Stempelseitiges Material: DX54D 1,5 mm (Rm: 270 - 330 N/mm 2)Matrizenseitiges Material: AlMg4,5Mn 1,5 mm (Rm: 255 N/mm 2)
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Peel Test Comparison of Joining Methods
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
1,8
0 1 2 3 4 5 6 7 8 9elongation (mm)
forc
e (k
N)
Stanznieten Ø5,3x5 H4 Vollnieten Ø5x4,2 ES Clinchen
Schälzugvergleich der Fügeverfahren Stanznieten, Vollnieten und Clinchen
Stempelseitiges Material: DX54D 1,5 mm (Rm: 270 - 330 N/mm 2)Matrizenseitiges Material: AlMg4,5Mn 1,5 mm (Rm: 255 N/mm2)
Self Piercing Rivetingwith Semi-hollow Rivet
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Quality-related characteristics of a Self Piercing Riveting Joint
StrengthShear tension forcesPeel forces
Evaluation of an OK-joint(1) Interlock x (min. 0,20 mm)(2) Interlock y(3) Remaining material thickness (min. 0,15 mm)(4) Adjacent rivet headThe area out of undercut (1) and penetration depth (2) results in the stability of a self piercing riveting joint. The larger this area, the higher the stability of the joint. In order to avoid a piercing through of the rivet, a remaining material thickness (3) is necessary.To prevent corrosion between rivet and plate, the rivet head radius (4) should lie against the die side of the plate.
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22
33
44
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Application Engineering / Joint Investigation
Alu-Alu, Alu-Steel, Alu-Magnesium-Steel, Steel-Steel, Steel-Magnesium,…
Rivet C 3,35 x 4 C 3,35 x 4,5 C 3,35 x 5 C 5,3 x 4 C 5,3 x 5
min. total plate thickness 1,80 mm 2,00 mm 2,50 mm 2,00 mm 2,20 mm
max. upperplate thickness 1,40 mm 1,60 mm 2,00 mm 1,60 mm 2,00 mm
min. lowerplate thickness 1,00 mm 1,00 mm 1,00 mm 1,20 mm 1,00 mm
Rivet C 5,3 x 6 C 5,3 x 6,5 C 5,3 x 7 C 5,3 x 7,5 C 5,3 x 8
min. total plate thickness 2,50 mm 3,00 mm 3,50 mm 4,00 mm 4,50 mm
max. upper plate thickness 2,30 mm 2,50 mm 3,00 mm 3,00 mm 3,00 mm
min. lowerplate thickness 1,00 mm 1,20 mm 1,20 mm 1,30 mm 1,30 mm
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High Strength Steel Applications
0
0,5
1
1,5
2
2,5
3
3,5
100 320 600 1000 1600
MPa
mm
Limits of SPR process: Max plate thickness / strength
Current strength limit for sheets on die side 600 MPa for volume production
Strength < 320MPa 320-560 MPA 560-1000MPa > 1000MPA
Steel Type Mild High strength Ultra High strength Mega High strength
Overview steel classifications (IFUM, University Hannover)
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Rivet Geometries
C - Type P - Type HSS - Type
Top: DX54D (1,5 mm)Bottom: AA5754 (3,0 mm)
Mild Steels, Medium Steels, Aluminum, Magnesium, Plastic
Top: DP1000 (1,5 mm)Bottom:AA5754 (3,0 mm)
Enlarged outer diameter;optimized cutting edgechamfer below rivet head
Ultra and Mega High Strength Steels
Top: DP600 (1,5 mm)Bottom: AA5754 (3,0 mm)
Reduced inner diameter; stiffercutting edge; chamfer below rivet head
Mild Steels, Medium Steels, High Strength SteelsPure Steel joints and in combination with Aluminum bottom material
Solid Punch Riveting
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Quality-related characteristics of a Solid Punch Riveting Joint
(1) Filled upper flute
(2) Head excess length
In order to achieve best results with the solid riveting technique, at least one flute should be filled with die-sided material. This is done with the help of the die that presses the material into the solid riveting geometry by means of punching.
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22
1
Clinch Process
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Quality-Relevant Characteristics of a Clinching Joint
(1) Interlock (min. 0,10 mm)(2) Neck width(3) Remaining material thickness (min. 0,40 mm)
The interlock size and the neck width define the stability of a joint. The remaining material thickness is used as a measurable process control parameter.
1
2
3
Joint Investigation
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Application Engineering / Joint Investigation
Determination of rivet and die geometriesVerification of requiredstrenghtsC-frame specification Acessibility study
One System for Three Processes
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Equipment Configuration - Modularity
Solid Punch rivets
Self piercing rivets
ClinchingERT Setting Tool
Modular constructionaccording to customer requirement
ERC ControlStandard TUCKER-control concept
FeedingERF for self piercing rivetsEPF for solid rivets
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Force[kN]
10
20
30
40
50
3 6 9 12 15 24 33
Nosepiececontact
18 21 27 30 Punch path (mm) after nosepiece contact point
minsheet thickness
max sheet thickness
Preclamping springis activated
Rivet contactpoint
Preclamping springSpiral spring
Trigger for plate thicknessmeasurement
plate thickness measuring viasleeve position
Rivetsignature
Pressure path
Envelopecurve
Trigger for rivetlenght measurement
Setting path
minrivet length
max rivet length
Sequence of a riveting operation
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Requirements in Volume Production – Parameter Monitoring
Force path measurement
Due to overlapping results no chance to detect NOK joints
Counter Start : 18225Counter End : 18924
Counter Start : 18925Counter End : 19483
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Requirements in Volume Production – Parameter Monitoring
Mathematic result evaluation
identic data to slide 21
Clear separation between OK and NOK
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Requirements in Volume Production – Data Management
POP Blind Rivet
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Blind Rivet Technology
Blind riveting in Carbon Fibre
Requirements
High Pull-together capability
Reduced surface/edge pressure
Reduced hole bearing
High pull out resistance
High Corrosion resistance � only Stainless A4
High shear & tensile strength
High mandrel head retention
Good waterresistance
Grip range as much as possible
Rivet Setting with conventional equipment
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Finding Solutions
No Go Critera
Limited in Application
Feature Vgrip Vgrip Plastics LSR TVD Closed End Multigripconventional POP
rivet
(Ø 4,8mm Metal-rivet; Ø 6,8mm VG-plastic)
Shape Blind head
Surface/ Edge pressure low very low low low high high
max. breakload ~ 8000 N ~ 670 N 4300 N 7900 N
Material Mandrel , Body A4/A4 Plastic/Plastic Steel/Steel ZiNi A2/A2
Pull-together capability good low good low bad bad
Grip Range 3mm 2mm 5mm 2mm
Water resistance good good no very good no
Mandrel head loosening force (at Room Temp.) > 1000 N >1000 N min. 0 N min. 0 N
Shear Strength(at Room Temp.) 4000 N 2015 N 2000 N 4300 N
Tensile Strength(at Room Temp.) 4500 N 600 N 2500 N 4800 N
Resistance to temperature very good low very good very good
Rivet length l max(at 2-4mm grip thickness) 13,2 mm 18,5 mm 19,5 mm 12,3 mm
Diameter Blindhead (Rivet set in application) 7,3 mm 9,5 mm 14,2 mm 6,6 mm
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VGrip Setting Process
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VERTRAULICH – Alle Rechte vorbehalten
Ø Studie: Metal VG-Stud / Sample: A2 DIN EN ISO 3506-1
Future Prospects
Emhart TeknologiesTucker GmbH
Max-Eyth-Str. 135394 Giessen
Tel. +49 641 405-0Fax +49 641 405-300
