TOX views itself as not just another machine builder TOX ... · machine builder and manufacturer ... • two or three layers ... Plate strength up to 1700 MPa up to 1200 MPa

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TOX®- Technology World-Wide

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Tochterfirmen Tochterfirmen / Subsidiary / Subsidiary Vertetungen Vertetungen / Representation / Representation

TOX views itself as not just another machine builder and manufacturer of products but as a manufacturing partner for forming, piercing, insertion and joining processes and the equipment that drives them!

TOX® -Clinching and Riveting

Fastener Insertion

S o l i d P u n c h R i v e t

TOX® – An International Equipment Supplier for:

SPR

TOX® Mechanical Joining Technologies

confidential

•  Introduction to:

•  Clinching

•  Clinch Rivet

•  Punch Rivet

•  Other Fasteners

•  Range of material for each process

•  Advantages & disadvantages of each process

•  Sample Applications

TOX® PRESSOTECHNIK 4

Phases of TOX®-Clinching

A B

C D E

Upsetting Lateral spreading of the die side material

Filling of the ring groove Lateral spreading of punch side material Finished TOX®-Round Joint

Interlock

X dimension

6 TOX® PRESSOTECHNIK

Performance What can the TOX Clinching Process Join!

Material: •  metallic and ductile •  same or different materials

Material thickness: •  same or different thicknesses (in the ratio of appr. 1:2 up to 2.5:1) •  min. single sheet thickness approx. 0.1mm •  max. total sheet thickness approx. 22.0mm Component layers: •  two or three layers •  sandwiched layers made of textiles, papers, plastic or adhesive Material surface: •  uncoated or coated (e.g. zinc coated, painted, plastic coated, etc.) •  oily or dry (some lubrication may be required)

1.0mm Alu 1.0mm Asi 304

3.0mm St 0.7mm St

1.0mm DX51 1.0mm DX51 1.0mm DX51

0.4mm St painted 0.4mm St painted


New Motto – Clinch wherever possible Because all rivets and welds are expensive

But what can TOX®-Clinching offer? Sheet metal strengths up to 1,200 MPa Smaller flange widths than other joints Leak-tight joints Smallest joining points, Ø1.5 mm for thinnest metal layers 0.1 mm Multilayer possibility, up to 4 layers Simplest installation Lowest cost per joint Best electrical conductivity

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Economy of TOX®

Cost comparison versus welding (in collaboration with a German automotive manufacturer)

Base: Steel 0.8 mm / 0.8 mm equipment depreciation over 6 years – includes consumables

18%

The Clinching Technology Current developments

Aluminium die casting Used for complex geometries often with high function integration and to transmit high forces and because it is cheap. There are some disadvantages: Easy cracking tendency with bad forming properties. “Compression is o.k., tension is bad“ Gas inclusions prevent hot joining processes

Origin: IFUM Hannover

Example suspension-strut dome,

The Clinching Technology Current developments Clinching with the TOX®-Round Joint! AlSi19MnMg 2.9 mm in CR240BH 1.5 mm in ENAW 5182 2.0 mm AlSi19MnMg 2.9 mm

No cracking of the Al casting material is noticable

Even both joining directions are possible!


High-strength TWIP and TRIP steels Now available with tensile strengths up to 1000 MPa! and elongation at break of 50 %! Used because of their high energy absorption capacity, for crash protection. There are disadvantages: High joining forces are necessary. The high manganese content prevents the hot joining processes because of breakage and deformation.


Clinching with the TOX®-Round Joint! Trip 700 1.45 mm in Trip 700 1.45 mm

DP 800 1.5 mm in DP800 1.5 mm DP 600 1.75 mm in DP 600 1.75 mm


Environment compatibility How can I avoid toxic fumes?

TOX®-Clinching is a cold forming process, therefore... à no auxiliary energy needed à no toxic fumes or gases, even with painted, coated or plastic insulated sheets

Resulting advantages for your production:

à daily energy savings

à no need for coolants or expensive inert gases

à no need for washing or surface treatments

à no disposal of chemicals or toxic waste


Quality assurance and process monitoring

Manual check: Checking of control dimension "X" with a scissor gauge.

TOX® PRESSOTECHNIK

Parameterization of the Clinch Joint

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Simple parameterization using our Electric Drive OR our Servo-controlled Powerpackage

TOX Joining process specific HMI for ease of operator understanding

TOX® PRESSOTECHNIK

Cross Section Analysis

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Checking the design parameters of the clinch point:

K. Schuhmacher

TOX® Joining Technology

TOX® Clinch Rivet

TOX® PRESSOTECHNIK – The Technologies

17 K. Schuhmacher

The TOX® Clinch Rivet


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Comparison TOX® Clinch Rivet / SPR Rivet



No pre-piercing required

Ability to join materials combinations where die side thickness is <0.7mm

Flexible joining method in regards to materials, sheet thickness variations and adhesive applications

Aluminium rivet for Aluminium materials resolving issues with corrosion

Tight sealed joint, which is of interest in high moisture areas

Flush surface on the punch side

Reasons for Clinch Rivet

TOX® PRESSOTECHNIK

Solid Punch Rivet

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Door - Sail Area -  Door 1

-  Body Sidewall 2

-  Fender 3

-  Trunk Pan 4

CLS SL S

1 1 1 1

1 2 3

4

SLS

Applications for Solid Punch Rivet

1 1


Fs

FN FN FP FP

Slugs die

Rivet punch Hold down device

Solid punch rivet

FS Punching force FN Clamping force FP Embossing force

Solid Punch Rivet Technology: ”the basics“

TOX® PRESSOTECHNIK

Solid Punch Rivet: comparison

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Solid Punch Rivet Self piercing rivet

Rivet is not deformed Bottom edge is opening up

Cutting edge

Rivet head

•  Even surface on punch side

•  Multi layers possible

•  Tolerates sheet thickness variations

•  Joining process monitoring is easy

Steel

in Al

Typical joining tasks of solid punch riveting

Al in Al

22MnB5-Steel

in Al

Some special requirements for this Technology

➢  Wishful thinking from design: Minimal rivet variants for different material thicknesses

Shown: Total material thichness 3,0 – 7,5 mm Spectrum of rivetlength 3,6 – 8,1 mm Resulting rivet protrusion 0,6 mm


No pre-piercing required

One die and one rivet for a variety of tasks

Flexible joining method with regards to materials and thickness variations

Only the die side material must have plastic deformation capability

Punch side materials may be high strength materials or non-metal materials

Even surface on the punch side and a minor rivet extension on the die side can easily be achieved

Reasons for Solid Punch Rivet

➢  complete process monitoring and documentation

Some special requirements for this Technologie

➢  Easy configuration with full overview despite complex technology.

Some special requirements for this Technologie

Other realized benefits

✓  For material strenghts up to 1700 N/mm2 with single material thickness of 1,8 mm

✓  Cycle time 4,5 s

✓  Fully redundant fault detection strategies

✓  Envelope and window monitoring

TOX® PRESSOTECHNIK

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TOX Process Development

TOX® PRESSOTECHNIK

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TOX-Assembly Systems

TOX® PRESSOTECHNIK

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TOX-Riveting Systems

SPR – System 80kN Powerpackage Driven 2 Size Rivet selection Process Monitoring

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RZKW 05.niet.240.100.12

TOX® - Powerpackage type RZKW-80 and RZKW-50 ✓  proven technology ✓  High velocities (max.1,5m/s) ✓ Warranty about 10 mio strokes in first year of

use ✓ Maintenance free (evtl. oil refill necessary) ✓  Easy an simple system ✓  integrated travel measuring (no reference

position necessary) ✓  No cooling times necessary ✓  Cost reduced control concept NEW: regulated power stroke by use of servo valves

TOX® self piercing rivet systems

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Deflector for blown out rivets

Easy mounting/dismounting for maintenance and cleaning purpose

Oscillating drive

Uncoupled, crossover area to feeding tube ✓  Easy adjustment dust gates:

✓  For assorting false rivet diameters

✓  dust separator

Pneumatic connections: ✓  False rivet lengthes are

blown out ✓  Supporting airflow

Sensor for filling-level

Sensor for rivet-length control, programmable

TOX® - rivet bowl:

TOX® self piercing rivet systems

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TOX® Rivet Systems – feeding tube

TOX® PRESSOTECHNIK

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• SPR – Setting Head • Active loading stroke

• Gun equalization

Special Execution for SPR - Die Driven

TOX® PRESSOTECHNIK

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Size Comparison of the Drives

Powerpackage 80kN with 12mm power & 300mm total strokes

Electric Drive 80kN / 300mm

Die driven mechanism for SPR

TOX® PRESSOTECHNIK Troy Waldherr, Tel.: 630.447.4611 38

TOX® – An International Supplier for Fastener Insertion

TOX® PRESSOTECHNIK Troy Waldherr, Tel.: 630.447.4611 39 38

TOX® – system to set pierce-nuts

Automated processing of pierce elements from different manufacturers

✓  studs

✓ round nuts

✓  rectangular nuts

✓  square nuts

✓  thread size M5 to M10

Complete TOX® pierce-element press


TOX®- Powerpackage

TOX®- pierce-nut -tool

TOX®- c-frame

TOX®- process device

TOX®- feeding device

competence from a single source

system - modules


system - characteristics

✓  magazine + pierce-nut head as an integrated solution

✓  reliable separation of individual nuts

✓  improved sensor detection

✓  slim tool for better accessibility

magazine

max. level

min. level

pusher-cylinder

element detection via sensor

pierce-nut head adjustable via standard-shim plates

integrated anti rotating device

NEW: development of a pierce-nut-head

slim tool geometry



✓  feeding device and control integrated in 1 unit ✓  space-saving solution ✓  USB – interface for user-login ✓  ethernet – interface for data storage ✓  hardware – interface according to customer requirements ✓  chute distance up to 10 m

6 bar

standard software – interface

hardware - interface

optionally:

➢  Interbus LWL 500 kBd / 2 MBd

➢  Profinet CU / LWL

➢  Profibus CU

➢  Ethernet

approx. 1000mm

approx. 800mm

NEW: feeding device including control

max. 10 m



TOX®- control device ✓  operated by touch-panel with graphics capable display ✓  manual mode / automatic mode ✓  display of system status via colored icons ✓  simplified error diagnosis ✓  storing process datas

TOX® process device => control + monitoring

control monitoring

+

TOX®- process monitoring ✓  force and travel monitoring ✓  individual analysis of force-displacement diagram by use of evaluation windows

+


customer benefits

cost savings ✓  reduced start-up periods ✓  pre-tested system => no expenses for programming ✓  standardized software-interface

system responsibility by system supplier

✓  correct process operations ✓  correct process monitoring

modular construction with proven TOX®-components

1 process device for the complete system ✓  integrated process monitoring => no additional monitoring device needed ✓  monitoring of the force-distance curve => archiving of process data ✓  avoid misuse and thus tool breakage

flexible use: ✓  hardware – interface according to customer requirements => Interbus – Ethernet - Profinet ✓  basic construction can be adapted to different types of elements

TOX® – An International Supplier Form and Pierce

Most Common Application:

-  Door lock

TOX® – An International Supplier Form and Pierce

Form and Pierce in different versions

Slot

M8 Countersunk

Diameter 30 mm

Pierce and Form in steps and the results

TOX® PRESSOTECHNIK

Presented by

Troy Waldherr

North American Sales Manager

TOX Pressotechnik LLC

Warrenville, IL 60555

(630) 447-4611

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TOX®- Joining Technology

TOX® PRESSOTECHNIK

Thank You!

Any Questions?

50

Overview of Mechanical Joining Processes

part 1

Punch Rivet Clinching Clinch Rivet SPR

- Size 4 rivet -

- Size 6 point -

- Size 5 rivet -

- Size 5 rivet -

Plate strength up to 1700 MPa up to 1200 MPa <500 MPa <1000 MPa 1

Multi-grip capability very good low low low Compensation for sheet thickness tolerances

very good good good good

Max. number of sheets 3 and more 3 (sometimes 4) 2 (sometimes 3) 2-3

Flush surfaces two-sided possible no one-sided 2 one-sided 2

Pressing force utilisation (shear strength/pull strength) 3

40-70 N/kN 80-100 N/kN

20-40 N/kN 20-40 N/kN

38-45 N/kN 60-75 N/kN

ca. 50 N/kN 4 ca. 100 N/kN 4

Quality Assurance envelope curves envelope curves envelope curves envelope curves

Tool life >250,000 5 >200,000 6 >200,000 6 >200,000 6

Pull strength (Al-Al) 7 1200 N-1500 N 600 N-900 N 1700 N-1900 N approx. 2000 N 4

Shear strength (Al-Al) 7 2000 N-2500 N 900 N-1100 N 2700 N-3200 N approx. 4300 N 4

1 In individual cases, ultra high strength sheets can be joined 2 Slight sheet metal entry around the rivet head 3 Point holding force per kN pressing force, Al 1.5 mm in Al 1.5 mm (à frame size) 4 Small database

5 "Start value" for an Al-Al joint (no reference values so far), level as for clinching 6 For Al in Al in reality sometimes much higher 7 Reference values for a joint mating Al 1.5 mm in Al 1.5 mm

Overview of Mechanical Joining Processes

part 2

Punch Rivet Clinching Clinch Rivet SPR

- Size 4 rivet -

- Size 6 point -

- Size 5 rivet -

- Size 5 rivet -

Robustness good 8 very good very good very good

min. flange width 9 12 mm 10 mm 14 mm 18 mm

Techn. availability high very high high high

Multi-point capability feasible very good feasible feasible

Machine complexity high 10 low medium medium

Cutting of the sheets yes no no yes, upper plate

Corrosion yes 11 no no yes 11

Liquid Tightness no yes yes no 12

Min. lower sheet thickness 1 mm 0.2 mm 0.7 mm 1 mm 13

Joining component costs 100% 14 none 50% (ca. 2 ct) 50% (ca. 2 ct)

Slug yes no no no 8 Due to the low amount of self-centring (rivet centricity) and variation in the degree of groove filling 9 The flange width can possibly be reduced by a die which is optimised for the interference contour 10 Slug disposal in addition to joint component feed

11 Sheets are cut through, no corrosion if joint points are painted 12 Upper sheet layer is punched through 13 Depending on the total sheet thickness 14 A forged rivet is at STR level

Projects in

the Car Industry


TOX Clinch Applications - Exterior


TOX Clinch Applications - Interior

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Engine hood with TOX® joints

125 TOX® joints Ø 8 mm Al 1.15 - Al 1,25 - Al 2.00 - Al 2.50 mm into Al 1.15 - Al 1.25 mm With 9 Robotic Clinch Units

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Decklid with TOX®

60 TOX® joints Ø 6 mm Sheet metal 0.75 mm into Sheet metal 0.75 mm with 2 Robotic Clinch Units

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Sunroof frame with TOX®

Dissimilar Materials

12 TOX® joints Ø 8 mm Anodized Al 2.00 mm into CRS 1.20 mm

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Car back wall

Mixed joining of steel with aluminium •  Adhesive + Clinching •  120 TOX® joints

Documents

TOX views itself as not just another machine builder TOX ... · machine builder and manufacturer ... • two or three layers ... Plate strength up to 1700 MPa up to 1200 MPa