GALM15    PRESENTATION

Henrob Self-Piece Riveting (SPR) An Overview and How To Optimize Its Use

August 2015

HENROB – WHAT WE DO

Ø  Our sole focus is the engineering and manufacturing of Self-Pierce Riveting Systems and Self-Piercing Rivets (SPR)

Ø  Acquired by Atlas Copco in September 2014

Innovative Joining Solutions

Courtesy of Ford Motor Company

HENROB - APPLICATIONS Current BIW SPR “Poster Child” – 2015 F150

Courtesy of Ford Motor Company

Courtesy of Ford Motor Company

Ø  2,200 to 2,600 SPRs per vehicle Ø  239 different material combinations joined by SPRs

Ø  62 material specifications (gauge/alloy/temper) Ø  Henrob direct involvement started in 2010

WHAT IS HENROB SPR

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“No hole” automated riveting

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2T Joint Steel to steel Aluminum to aluminum

Multiple Layer Aluminum alloys up to 10 mm Mild steel alloys up to 6 mm

Dissimilar Metals Aluminum to steel to aluminum

Dissimilar Materials Plastic / aluminum

HENROB – IN BIW Joining Capabilities

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HENROB – IN BIW / CIW Recent Henrob SPR Developments

T-Rivet Geometry 3T Aluminum with Adhesive 3mm + 3mm + 2.7mm

T-Rivet Geometry 3T Aluminum with Adhesive 0.9mm + 3mm + 3.2mm

Self-Piercing Stud (SPS) M6 in 2.3 mm Aluminum

WHAT'S CRITICAL TO SPR - JOINT

Rivet  Inser7on  Direc7on  

Rivet  Inser7on  Direc7on  

Rivet  Body  Geometry  

Parameters

Preferred - Thin to Thick Bottom sheet is >33% of the total stack •  Better strength consistency •  Easier rivet rationalization •  Less chance of rivet tail

breakthrough

Non-Preferred - Thick to Thin

Bottom sheet is <33% of the total stack •  Lower strength consistency •  Difficult rivet rationalization •  Increased chance of rivet tail

breakthrough

General Design Rule

WHAT'S CRITICAL TO SPR - JOINT

Joint Development Testing

Riveted “coupons” are made using the application materials to test joint strength and integrity.

WHAT'S CRITICAL TO SPR - JOINT

WHAT'S CRITICAL TO SPR - EQUIPMENT

Ø  Access to joint(s). Ø Directional process

Ø  Type of riveting tool Ø Robot mounted Ø Pedestal mounted Ø Manual

Ø  Type of feed system Ø  Tape or loose

Ø  Throughput requirements Ø  Jobs per hour (JPH)

Ø  Grouping of joints Ø  Clearance around fixture tooling

Servo  Rivet  Se*er  

Rivet  Spool  

Die  Post  

Feed  System  

C-­‐Frame  

Mount  

Required Process Inputs

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BIW TRENDS Material Make-up of SPR Joints

AL  Sheet    

AL  Cas=ng    

AL  Extrusion    

AL  Sheet    

AL  Cas=ng    

AL  Extrusion    

HSS  Steel  

PHS  Steel    

AL  Sheet    

AL  Cas=ng    

AL  Extrusion    

HSS  Steel  

PHS  Steel    

Mg  Cas=ng    

Composites    

15 - 18 years ago 5 - 8 years ago 5 - 7 years from now

OPTIMIZING THE USE OF SPR

Ø  Minimize the number of unique joints •  Material types and gauges •  Insertion direction •  With and without adhesive •  Loading conditions

Ø  Early testing and validation is key to success

Ø  Establish realistic SPR standards •  Head height •  Interlock •  Bottom thinning (tmin)

Ø  Manufacturing strategy needs to aligned with product development and design

OPTIMIZING THE USE OF SPR

Ø  Reduce learning curve utilizing vendors with previous experience

Ø  Utilize vendor resources at every level of product design cycle through launch

Ø  Early engagement with is critical !