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5 Mechanical joining ...................................................................................................................2 5.1 Introduction.......................................................................................................................2 5.2 Comparison of properties of some typical mechanical joints ...........................................4 5.3 Example: Hardtop Porsche 911 Cabrio............................................................................5 5.4 Example: Self-piercing riveting of dissimilar materials .....................................................6 5.5 Example: Joining by screws .............................................................................................7 5.6 Hemming ..........................................................................................................................8 5.6.1 Process principle.......................................................................................................8 5.6.2 Flat and "Rope" hem .................................................................................................9 5.7 Bolting ............................................................................................................................10 5.7.1 General remarks on bolting with fasteners and inserts ..........................................10 5.7.2 Press nuts and bolts Features and process ........................................................11 5.8 Clinching .........................................................................................................................12 5.8.1 Principle methods and application potentials .........................................................12 5.8.2 Single-step clinching Process steps ....................................................................13 5.8.3 Quality-criteria for a connection ..............................................................................14 5.8.4 Design criteria .........................................................................................................15 5.9 Self piercing riveting .......................................................................................................16 5.9.1 Self piercing riveting Principle..............................................................................16 5.9.2 Design criteria .........................................................................................................17 5.9.3 Quality-criteria .........................................................................................................19 5.9.4 Self-piercing bolts and nuts ....................................................................................20 5.9.5 Riveting process Self-piercing nuts .....................................................................21 5.9.6 Types of self-piercing bolts and nuts ......................................................................22 5.10 Blind riveting .................................................................................................................23 5.10.1 Blind rivet systems Rivets, Nuts and bolts.........................................................23 5.10.2 Blind rivet and riveting process .............................................................................24 5.10.3 Blind rivet types.....................................................................................................26 5.10.4 Blind riveting bolts and nuts ..................................................................................27 5.10.5 Riveting process Blind riveting bolts and nuts ...................................................29 5.10.6 Types of blind riveting bolts and nuts ...................................................................31 5.11 Self threading screws ...................................................................................................32
5 Mechanical joining
5.1 Introduction
Literature: Hahn, O.; U. Klemens, Fgen durch Umformen - Nieten und Durchsetzfgen Innovative Verbindungsverfahren fr die Praxis. Dokumentation 707, Dsseldorf: Verlag und Vertriebsgesellschaft, 1996, ISBN 3-930621-56-8 Klemens, U. and Hahn, O.: Nietsysteme, 1994, ISBN 3-922293-32-8 Ostermann, F. and 8 Co-authors, Aluminium Materials Technology for automobile construction, English translation edited by Roy Woodward, London Mechanical Engineering Publications Limited, 1993, ISBN 0 85298 880 X Ostermann, F., Anwendungstechnologie Aluminium, Berlin, Heidelberg, London, New York, Tokyo: Springer-Verlag, 1998, ISBN 3-540-62706-5
Section of hardtop Porsche 911: blind-riveting nuts and self-piercing rivets Source: LWF-Univ. Paderborn Because of the sensitivity of work-hardened and age-hardened aluminium alloys for the heat input from fusion and resistance spot welding and due to the effects of oxide films on RSW electrode life the use of "non-thermal" joining techniques have gained particular importance in automotive applications. Mechanical joining techniques like bolting, self-piercing riveting, blind riveting, clinching and the combination of these techniques with adhesive bonding have, therefore, been developed to substitute the traditional resistance spot welding. The different mechanical joining methods have found application in the joining of sheet components and also for use in joining of extrusions and castings. Some examples are depicted in the figure below.
Typical mechanical properties of some mechanical joining methods Source: Niedermeier, Alcan Contrary to screw bolt joints, mechanical joints are generated by local plastic deformation of either the fastener or the work-piece or both. For this reason joint properties depend strongly on the chosen tooling and fastener parameters. Please contact the tool or fastener supplier for details.
Aluminium side impact beam with steel sheet stampings joined by riveting (Opel Astra) Source: Alcan
5.6 Hemming
Step 1: bending 90, Step 2: hemming 45, Step 3: folding 180 Source: Anwendungstechnologie Aluminium
In order to maintain the bead (rope hem) radius during the final folding operation, the punch can be designed with an inclined surface with an angle to the horizontal which can be varied, depending on the sheet thickness and the minimum allowable inside bending radius, see figure below.
5.7 Bolting
5.7.1 General remarks on bolting with fasteners and inserts
See also: AAM Joining 1 Fusion welding > Stud welding AAM Joining 5 Mechanical joining > Self piercing riveting AAM Joining 5 Mechanical joining > Blind riveting > Blind riveting bolts and nuts Bolted or threaded connections for the attachment of equipment to aluminium components and structures may be achieved by simply bolting through the aluminium part in a comparable way as for conventional blind riveting. It is often necessary to provide internal support if bolting through a closed section such as for the engine or suspension attachments to the body front rails. This support can be with tubes or extrusions fixed inside the section to prevent the section from collapse under high installation loads. Bolted connections can also be achieved with threaded studs and nuts fixed to the aluminium part. Aluminium threads are not recommended for situations where frequent removal for service is required, but can be applied for lightly loaded connections for internal trim, electrical harnesses, equipment attachment etc. Care must be taken if bolting material combinations are used, which are critical with respect to galvanic corrosion. Except for stainless steel, all steel inserts assembled into aluminium parts must be coated to prevent galvanic corrosion. Insert manufacturers can supply a range of suitable coatings. Sealants, gaskets or protective coatings may be required in severe corrosive environments, whereas simple surface treatment of the steel and/or the aluminium may be adequate in a dry internal environment. Aluminium welded studs and nuts are available (s. LINK) that may be welded directly to the aluminium parts by an electric arc welding process. Alternatively, steel threaded studs and nuts may be installed for applications where higher strength or frequent dismantling may be necessary. The selection of insert type depends upon the strength (torque) required and whether access is only possible from one side (blind) or both sides of the aluminium part. Steel inserts for studs and nuts are available that can be installed in pre-pierced holes in the aluminium part. The insert installation can sometimes be incorporated in the press line after the forming, trimming and piercing operations for a stamped part. Of course, they can be also installed separately at any stage in the assembly sequence including in-process and inservice repair. Fixed studs and nuts are also available that do not require pre-pierced holes and which can be installed in a single operation in the press line or as a separate operation. Fixed nut inserts are available that are sealed to prevent any leakage through the joint. Some fixed stud and nut inserts leave a raised element on the opposite side that must be allowed for in the design of subsequent assembly of the part. Due to the large variety of possible solutions, no performance values can be quoted here, please refer to product suppliers for more detail information.
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5.8 Clinching
5.8.1 Principle methods and application potentials
Clinching involves the joining of two materials by local forming and does not require an extra fastener. A punch forms the two materials to be joined into a die. A button is formed on the underside and provides an interlock between the sheets. Clinching works with aluminium combinations, with multi-material combinations, like aluminium and steel, and also with pre-coated or galvanized materials. Clinching can also be combined with a sealant or an intermediate layer that acts as a sound dampener. The clinching process doesn't build any thermal stresses into the work-piece, so a clinched joint performs well where there's the potential of thermal fatigue or heat. The two main principles in clinching are single stroke and double stroke. Single-stroke clinching requires special tool sets for each set of parameters, especially sheet thickness. While double-stroke clinching can adapt to a range of thicknesses, it requires a larger capital investment and is difficult to integrate into the stamping press line.
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Single-step clinching without cutting Step 1:The punch and blank holder move downward, the work pieces are clamped and fixed by spring force of the blank holder. Step 2: By action of the punch the material flows into the bottom die cavity forming a cup. The process parameters and dimensions of the punch and die are finely tuned to the sheet thicknesses of the work pieces. This insures that no material is laterally drawn into the joint from surrounding area. Step 3: Finally, the thickness of the cup's bottom is reduced by upsetting and the material forced into the die groove and in lateral direction, forming the necessary undercut. Step 4: After reaching a preset maximum force (force control) or a preset displacement (stroke controlled), the punch is retracted and the clamping force relieved. The joint connection requires no finishing.
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The button may otherwise burst out of the edge of the flange or cause distortion in the joint. Proper overlap of the layers to be joined and a correct flange width will also help ensure proper alignment between the work-piece, punch and die. A pre-clamping step may be helpful if joining a flange width close to the minimum width is to be undertaken. The clinch spots should be spaced to avoid contact with previously driven clinch spots or the strained area immediately around them. Placing several clinch spots too near to each other may cause distortion or some bending of the joint. A pre-clamping step can help to minimise this. A sufficient number of clinching spots must, however, be used to guarantee the overall design strength of a section. A precise relationship between part fit-up, alignment and joint quality is not easy to quantify. However, good control of these two variables will help ensure that the layers of material to be joined are drawn together properly as the clinch spots are driven and set. In addition, force will not be diverted into pressing parts.
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Since the rivets are made of harder material than the work pieces, riveting over an existing joint may result in serious damage to the tooling. Placing several rivets too near to each other may cause distortion or some bending of the joint. A pre-clamping step can help to minimise this. Poor fit-up and alignment may reduce joint performance and accelerate tool wear.
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Recommended Joint Design Flange width should be sufficient to contain deformed rivet and sheet Ensure adequate spacing between rivets Ensure good fit up of stampings. A precise relationship between part fit-up, alignment and joint quality is not easy to quantify. However, good control of these two variables will help ensure that the layers of material to be joined are drawn together properly as the rivets are driven and set.
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5.9.3 Quality-criteria
In self-piercing riveting with semi-tubular rivets as well as with solid rivets, the strength of the joint is determined by the amount of undercutting as shown in the figures below. Since the tool and rivet dimensions are carefully tuned to each other and to the joint thickness, the amount of interlock is determined by the "compression measure" (s. figures below), which can serve as a non-destructive quality criterion when compensated for the position of the rivet head within the joint. The figures below show quality relevant measures for joints with semi-tubular and solid rivets.
Semi-tubular rivet
Solid rivet
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Geometrical parameters
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Riveting process: self-piercing nuts Step 1: Blank and self-piercing nut are both positioned. Step 2: In a single-step mounting process, the joining element punches a hole through the sheet blank and in combination with the die generates a positive connection with the material of the sheet blank. In the process, material flows into a circumferential groove. Step 3: The punched slug is pressed out of the sheet blank by an ejector. Step 4: The joint has been created. As a rule, the geometry of the nut does not undergo any alteration. The joint is flush on one side.
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Blind riveting process The blind rivets are classified in categories A, B, C and D (s. Lit.). For structural purposes the C and D categories have to be chosen.
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Geometrical parameters
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