Next Generation Fastener Technology
Andreas Lembach
Mechanical Joining of Composites in High Volume Production
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GALM Series, Automotive Lightweight Materials Manufacturing Congress Europe, Birmingham, 2016.
M.Sc.(TU) Dipl.-Ing.(FH) Int. Welding Eng.(IWE) Andreas Lembach
Technical Development PROFIL Verbindungstechnik GmbH & Co.KG
Next Generation Fastener Technology
Andreas Lembach
Content
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- Company Background- Motivational Design example- General Issues with composites- Solutions
• Running• Developing• Brand new
Next Generation Fastener Technology
Andreas Lembach
PROFIL: Your system supplier for pierce nuts and studs
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Next Generation Fastener Technology
Andreas Lembach
Example of a typical PROFIL Solution
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Next Generation Fastener Technology
Andreas Lembach
Joining of two composite panels with nut and bolt
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strain
FF
Next Generation Fastener Technology
Andreas Lembach
Design example
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PA6 max surface pressure --> 80 N/mm²-wet, warm, reducing creep --> 5 N/mm²M8 nut/bolt max load (class 8 / 8.8) --> 21 kN--> Necessary washer diameter --> ~40 mm
Washer deformation
2,1 t
Next Generation Fastener Technology
Andreas Lembach
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[Schürmann, Konstruieren mit Faser-Kunststoff-Verbunden]
surface pressure [N/mm²]
Increasing washer thickness
Washer design balance
Worst case scenario
Next Generation Fastener Technology
Andreas Lembach
General Issues with Composites
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- Corrosion- Viscoelasticity (Creep)- Cutting Fiber/ Cutting Material- Delamination- Small bearable surface pressure- Variety of production processes- Variety of material properties- Anisotropic Material properties
Next Generation Fastener Technology
Andreas Lembach
Recommendation in literature for the connection of two panels:
Rivet joint
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[Schürmann, Konstruieren mit Faser-Kunststoff-Verbunden]
Recommendation in literature for threaded application: Bonding fastener
Next Generation Fastener Technology
Andreas Lembach
Rivet joint with thread --> rivet nut
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Next Generation Fastener Technology
Andreas Lembach
Comparison with bonding
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Force transmission through rivet directly through all layers of material
Force transmission through flange, layer of glue and layer of matrix material before first layer of fibers
Next Generation Fastener Technology
Andreas Lembach
KZB Fastener for bonding or laminating
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Next Generation Fastener Technology
Andreas Lembach
Warm hole forming
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Top View
Side View
2.Step riveting
Next Generation Fastener Technology
Andreas Lembach
1 2
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RSP warm hole forming and riveting in one step
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Next Generation Fastener Technology
Andreas Lembach
KSB SBF RSF in two steps
15Cold punching and riveting
Next Generation Fastener Technology
Andreas Lembach
SBF - stud
Composite
Washer
Die button
Selfpiercing SBF in Composite in one step
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Next Generation Fastener Technology
Andreas Lembach
Stainless Steel Bolt
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- Marine grade material - Food industry- Chemical industry - Corrosion resistance - Cold forging --> cost effective production
in stainless steel metal sheetin Carbon reinforced material
Aluminum Steel with special zinc coat Stainless Steel
12 weeks salt spray + temp variation
Next Generation Fastener Technology
Andreas Lembach
Applications in Research projects
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University Aachen, Germany-Inprolight-
Fraunhofer, Germany-Eprofit-
Next Generation Fastener Technology
Andreas Lembach
Applications in Industry
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Mercedes: trunk Porsche: rear shelf
Next Generation Fastener Technology
Andreas Lembach
Problem: Delamination
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Others: Self piercing rivets
PROFIL: SBV Solid rivet with washer
Next Generation Fastener Technology
Andreas Lembach
SBV – piercing material with preload
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• No cleaning or preperation of surface necessary.• Ultimate strength immediately available• Reliable process.• Good crash performace.• All BIW Materials• Independent of the stack thickness
Next Generation Fastener Technology
Andreas Lembach
SBV – piercing material with preload
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• No cleaning or preperation of surface necessary.• Ultimate strength immediately available• Reliable process.• Good crash performace.• All BIW Materials• Independent of the stack thickness
Next Generation Fastener Technology
Andreas Lembach
Next Generation Fastener Technology
Andreas Lembach
Next Generation Fastener Technology
Andreas Lembach
Next Generation Fastener Technology
Andreas Lembach
Thank you for your attention
See you at our booth
26GALM Series, Automotive Lightweight Materials
Manufacturing Congress Europe, Birmingham, 2016.