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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


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


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


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


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)


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)


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)


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


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


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


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


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


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%


End Result: Complete LBM product line

NEXT: Installation process and equipment…


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?”


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


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?”


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?”


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


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?”

weight reduction in class 10 joints - lbcg.com · weight reduction in class 10 joints explore the...

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