flexible material joining technology for tomorrow`s ... · pdf fileflexible material joining...

Flexible material joining technology fortomorrow`s innovative lightweight designHolger Schubert, Dr. Jörg MöhringProduktions- und Werkstofftechnik PWT/VFT Bad Nauheim, 18.04.2012

Flexible material joining technology for tomorrow`s innovative lightweight design2

increasingcomplexity

changingproduct cycles

serious prediction

time

dem

and

volatilemarkets

zero emissiondriving

life cycle

varia

nts

Product innovations

today

cycl

etim

e sp

read

allocation

Today´s challenges in automobil production

flexibilityin production

expansion product line-up

dem

and

time

P1 P2 P‘2P‘1 P1 P‘2

today


Which materials should be joined?

thermal- spotwelding- fusion welding- laser welding- soldering

mechanical- riveting- clinching- FlowDrillScrew (FDS®)- ImpAcT – Tac Setting (RIVTAC®)

similar + hybridsimilar (St/St; Al/Al)

one side accessibility- FlowDrillScrew (FDS®)- ImpAcT – Tac Setting (RIVTAC®)- blind rivetting

two-sided accessibility- semi tubular punch rivetting- full punch rivetting- clinching

accessibility?

joining technology

Increase of crash-performance andtorsional stiffness Weight reduction by the

use of highstrength steeland lightweight materials Cost reduction

New challenges forjoining technologies

Mercedes SL

Increasing requirements concerningmodern car body concepts


No pre-hole needed

One side-accessibilty

Standard tac for all applications

Joining of profile-intensive multi-material designs

Joining of multi layer (> 6 mm)

Joining of metal and FRP

Combination with bonding

Noise protection needed

Local deformation of joining spot

Tac extension to be considered

al-sheet/al-profil

al-sheet/al-cast

multi-layer-

-

al-sheet/st -sheet

st -sheet/st -sheet

combinationwith bonding

FRP/al sheet

ImpAcT - field of application ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


Process steps:

1. First contact between tac and sheets

2. Penetrating sheets

3. Enlarging the material and building the characteristic rim hole

4. End of the joining process by reaching the final tac position

part

Tac

piston

Process description ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking

1 2 3 4

F (? 20 kN)

v

-sheet

11 22 33 44v (20 - 40 m/s)

-

11 22 33 44

F (? 20 kN)

v

-

11 22 33 44v (20 - 40 m/s)

Tac

base -

cover sheet


implementing decision:target type: SL-Class

Start-up: SL-Class

transfer decision:New MB - Projects

Start

Basics strength performance

2007 2008 20102009 2011 2012

Basic Testing Tape Feed

SL– Prototype Phase

CorrosionProtectionrelease

Control unit &+ Process control

ProcessSimulation

ComponentCrash-Test

Basics Joining process

PrototypeTesting BlowFeed

Ø 3,2 mm

Ø 6 mm

M

Dru

ck

Zug

H2- embrittlementTests

New Equipment MagFeed

StiffnessSimulation+ PPG

principlematurity

conceptmaturity

seriesmaturity

ImpAcTtechnology-release

Field testE-Class

Timeline Project ImpAcT

W175

W67W138

W104

ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


Critical loading direction for ImpAcT joints: cross tension Similar strength in case of shear tension Excellent performance in combination with bonding

WerkstoffeDeckblech: AC300Basisblech: AC300

AusgangsblechdickenDeckblech: 1,5 mmBasisblech: 3,0 mm

HilfsfügeteileRIVTAC® - Setzbolzen

FDS® - Schraube M5 x 18

SetzgerätRIVTAC® - BlowFeed System

Weber WSG 100

PrüfartQuasistatischer Zugversuch

Prüfanordnung

PrüfmaschineZwick 1484

Prüfgeschwindigkeit10 mm/min

0,0

2,0

4,0

6,0

8,0

10,0

12,0

14,0

16,0

18,0

Kopfzug Scherzug Scherzug + Klebstoff

Kra

ft F

[kN

]

ImpAcT FLS

Strength comparison between ImpAcT and FLS ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


Loading unit- Vibration conveyor- Control box- 3 supply tracks

(each 90 Tacs)

Tac setting tool- Supply unit- Setting head- Spiral magazine

(90 Tacs)

Pressure unit- Pressure booster- Compressed air tank

Noise absorbing cabinet- - 40 dB(A) reduction

ImpAcT – system equipment ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


100% online process monitoring Force and path monitoring with check against reference Optimization process for each joining point possible

Kraft

Weg

ImpAcT - process monitoring ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


ImpAcT – QS-Visualization

Overview of joining quality per comp.• green: OK• red: not OK

Quality stop and in caseof an imperfection: rework

Statistic function allowseasy process analysis

61000373

fault

ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


Sindelfingen

Rear floor BR 212

08.2010 – 04.2011

> 160 000 tacs

Location:

Part:

8 tacs per vehicle

period:

amount:

(Tacs in addition to RSP)

Validation / verification of suitability for series production

Verification of process-monitoring under production conditions

Targets:

Operational test rear floor BR212 ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


Stiffness simulation

Mises-Spannungen

Process simulation

Good accord with experiment Validation shows agreement with reality Optimization production suitable design

ImpAcT - Simulation results


Aluminium casting44%

Aluminium Profil17%

Aluminium Sheet28%

Steel8%

Other3%

Z2.3 – without hang on parts

Weight reduction: 110 kg

Mercedes SL-Class: body architecture ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


Targets:

Joining- Real parts

- Suitability for series productionMonitoring

- Process-monitoring

- Sensor system

Check- QS-control loops

- Testing methods

Rework

Training

Process -chain

Aluminum cast

Aluminum sheet

Aluminium profil

Series FLS (flow drill)

Verification of complete process-chain including testing methods

Implementing Q-Stop procedure including 3 step QS-control loops

1. Step: Tacs in addition to FLS

2. Step: Substitution of FLS

ImpAcT at Mercedes SL- class ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


Impact - at Mercedes SL- class Station layout

robot

loadingunit

clamping

HMI

noise protection cabinet

Layout allows joining in cycle time Noise protection cabinet necessary Standard HMI for visualization and

process-control

ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


FLS ImpAcT

Impact - at Mercedes SL- classVideo

ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


Conclusion

Hybrid material joinings with increasing costs, complexity and requirements

Only with innovative joining technologies this trend can be inverted

ImpAcT- technology offers a lot advantages due to material flexibility andprocess velocity

Mercedes- Benz is the first car manufacturer worldwide, starting with ImpAcTin series production

ImpulsAccelerated

Tacking

ImpulsAccelerated

Tacking


Thank you for your kind attention

flexible material joining technology for tomorrow`s ... · pdf fileflexible material joining...

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