1 RIFAST - One System Endless Possibilities © RIFAST Systems – Feb 2017
Weight Reduction In Class 10 Joints Explore The Benefits Of Lightweight Clinch Nut System
Viral Varshney February 22nd, 2017
2 RIFAST - One System Endless Possibilities © RIFAST Systems – Feb 2017
Who is Rifast Systems, LLC?
• We focus on the customer • We respect each other and create trust
• We strive for Continual Improvement • We take pride in our success
• We act as a team • We demonstrate a commitment to integrity and ethics
3 RIFAST - One System Endless Possibilities © RIFAST Systems – Feb 2017
Who is Rifast Systems, LLC ?
Rifast Systems, LLC is your complete source for clinching solutions.
§ Clinching Products
§ Engineering Experience Providing Customer Solutions
§ Applications Lab
§ In die/off Line Installation Equipment
§ Service and Training
4 RIFAST - One System Endless Possibilities © RIFAST Systems – Feb 2017
America Europe Asia
RIFAST® Systems LLC (Lincolnwood, USA)
RIBE® Verbindungstechnik RIFAST® Systemtechnik
(Schwabach, Deutschland)
RIBE® Joining Technologies Shanghai (Jiading, China)
Licensee Brasil: Bollhoff Service Center Ltda., Brasil
Agency Spain: COMERCIAL URCELAY , S. A.
Agency Nagoya, Japan: Rifast Sales office
Agency South Korea: RIFAST Systems
RIFAST® - Global Footprint
5 RIFAST - One System Endless Possibilities © RIFAST Systems – Feb 2017
EVOLVE
TEST
LEARN
OEM targets and strategies to reduce weight › Advanced Steels › Aluminum › Composites › Mixed materials › Joining solutions
› LBM (Lightweight clinch nut) › Clinch design for >700 Mpa materials
› Test and Launch LBM product line (Complete) › >700 MPa design (In progress)
6 RIFAST - One System Endless Possibilities © RIFAST Systems – Feb 2017
Learn Industry Need:-
› Down-gaging the material › Reduce fastener weight while maintaining class 10 clamp load performance › Reduce BOM part numbers (One fasteners for multiple applications) › Process time reduction (In-die v/s Offline)
Rifast Product line features:-
› Industry leading torque-out performance in Aluminum › Part design versatility (One design for > 2.5 mm thick material) › Automated installation (In-Die and Offline)
Existing Market Product performance:-
› Good performance in advanced steels (~ 1200 MPa) › Part versatility for self-piercing
› Self-pierce up to 4.0 mm material thickness › Automated installation (In-Die and Offline)
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Learn Industry Need is met:-
› Down-gaging the material › Clinch fasteners for Advanced steels › Self-piercing nuts and studs
Industry Need is partially met:-
› Reduce fastener weight while maintaining class 10 clamp load performance › Minor light weight designs from the fastener industry but the OEMs are asking for
more Industry Need NOT met:-
› Reduce Bill of Materials (BOM) part numbers (One fastener for multiple applications)
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Evolve Solution:-
› Reduce fastener weight › Reduce body (nut) diameter
› Maintain class 10 clamp load capacity › Maintain supported torque out performance › Maintain unsupported torque out performance
› Reduce body (nut) height › Maintain class 10 clamp load capacity › Maintain supported torque out performance › Maintain unsupported torque out performance
› Design one fastener for 1.0 mm to 4.0 mm material thickness (Use DBM as baseline) › Modify existing Rifast clinch geometry
› Optimized push-out performance › Optimized for unsupported torque out requirements
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Lower but Optimized Performance Unsupported torque: › Applied directly on the nut to test clinched joint torsional strength › NOT applied during bolt assembly (bolt applies supported torque during assembly) › Potentially be applied during service repair of the assembly if the joint has corrosion Supported torque: › As torque is applied, the nut is further clamped into the sheet metal, reducing the
possibility of spinning during installation
Push-out: › Applied in the opposite direction of clamp to test joint strength › NOT applied during bolt assembly (bolt pulls the nut further into sheet metal as
torque is applied) LOGIC behind Rifast focus on LBM design:- › Ensuring property class 10 to have lowest impact on customer assembly installation
process › Optimize unsupported torque out performance to meet joint strength requirements
before assembly
Unsupported Torque
Push-out Force
10 RIFAST - One System Endless Possibilities © RIFAST Systems – Feb 2017
How? Rifast rib performance in Aluminum
› Rifast technology relies on material flow into Rifast part features to create the clinch joint
› The 8 ribs in standard Rifast design provide the needed torsional strength to the joint.
Material flow during installation Material shear after destructive unsupported torque test
Material Flow effects on joint:- › Volume of material flow causes the significant localized increase in strength of the sheet
metal. › This localized zone in the sheet metal is between the ribs of the Rifast part › Joint failure happens when these ribs shear through the locally hardened sheet metal
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How? Rifast rib performance in Aluminum
› DBM unsupported torque out performance exceeds 75% of ISO 898-1 P.C. 10.9 bolt torsional strength (P.C. 10.9 bolt as used in production assemblies)
› Opportunity to reduce weight by optimizing unsupported torque performance
* Tested using ISO 898-1 P.C. 12.9 test bolts
Rifast rib profile allowed significant weight reduction at optimized unsupported torque performance that resists rotation during mating assembly component installation
DBM FailureModeM5 M6 M8
UnsupportedTorqueout(Nm) 20* 20* 29* Fastenertosheetmetalsepara6on
SupportedTorqueout(Nm) ISO898-2P.C.10 Threadstrip
Ma:ngBolttorsionalstrengthperISO898-7P.C.10.9(Nm) 9.3 16 40 Torsionalboltshear
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Evolve – New Design and TEST LBM Features
› Reduced fastener weight by 46% to 75% depending on thread size › Reduced body (nut) diameter
› Maintained class 10 clamp load capacity (class 10 nut per ISO 898-2) › Maintained supported torque out performance (class 10 nut per ISO 898-2) › Reduction in unsupported torque out performance (up to 50% reduction in worst
case) › Reduce body (nut) height
› Maintained class 10 clamp load capacity › Maintained supported torque out performance
› Modified clinch geometry functional in 1.0 mm to 4.0 mm material thickness › Reduction push-out performance (up to 60% reduction in worst case)
Weight(g) UnsupportedTorqueOutPerformance(Nm) Push-outPerformance(kN)
DBM LBM Reduc:on% DBM LBM DBM LBMM5 5.8 1.5 75 20 10 3.1 1.0M6 5.4 2.3 57 20 14 3.1 1.1M8 10.3 5.5 46 29 25 3.8 1.9
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Proof in the Math.. M6 DBM ribs
M6 LBM ribs
M6 LBM installed
Other factors that increase torsional performance:- › Material trapped between pilot and ribs › Surface force effects between nut and sheet metal
M6 DBM installed
M6DBM LBM
RibWidth 100% 64%RibHeight 100% 100%Ribcross-sec6onalarea 100% 64%Numberofribs 8 10Matl.ShearStrength(MPa) 275 275Shearloadrequiredtorotatenut 2,200 1,759TotalTorsionalStrength(UnsupportedTorqueOut) 18 12%reduc:onintorsionalstrength(UnsupportedTorqueOut) 33%%reduc:onasnotedfromtes:ng 30%
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End Result: Complete LBM product line
NEXT: Installation process and equipment…
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Installation Equipment: In-Die Intro to current systems – Customer feedback
“These things are tanks” “They run like clock-work” “We like the multiple fail-safes” “Poke-a-yoke? Nice!!”
“The heads are too big” “Why do you need to hook to my press?” “Why so many sensors?” “Can you install at an angle?”
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Installation Equipment: In-Die
Design Language:- › Flawless installation in the press
› Don’t cycle the press if the fastener is not there to install › Single piece flow to installation point
› Send ONE fastener at a time ONLY when it is needed › Protect the installation equipment from “manual over-ride”
› Multiple fail-safes from feeder to the installation point › Modular
› Easy custom designs based on press tool › Mechanical and Pneumatic systems feed fasteners
› Defined controls on input variables for consistent error-free processing
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Installation Equipment: In-Die
“These things are tanks” “They run like clock-work” “We like the multiple fail-safes” “Poke-a-yoke? Nice!!”
“The heads are too big” - Design language “Why do you need to hook to my press?” – Design language “Why so many sensors?” - Design language “Can you install at an angle?”
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Installation Equipment: Offline Intro to current systems – Customer feedback
“Design is good but how is it different from others?” “Automatic feeding.. Nice” “We like the multiple fail-safes” “Poke-a-yoke? Nice!!”
“Force Monitoring?” “Operator safety?” “Air pressure requirements – 6 bars?”
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Installation Equipment: Offline
Design Language:- › Flawless installation
› Don’t cycle if the fastener or the stamping is not there › Single piece flow to installation point
› Send the fastener ONLY when it is needed › Protect the installation equipment from “manual over-ride”
› Multiple fail-safes from feeder to the installation point › Operator Safety
› Energy control and fail-safes to release stored power
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Installation Equipment: Offline
“Design is good but how is it different from others?” - Design language “Automatic feeding.. Nice” “We like the multiple fail-safes” “Poke-a-yoke? Nice!!”
“Force Monitoring?” “Operator safety?” “Air pressure requirements – 6 bars?”