TALAT Lecture 4103: Self-Piercing Riveting
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This lecture describes the processes of self-piercing riveting, which is a relatively new fastening method for sheet metal parts. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lecture 4101 is assumed.
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TALAT Lecture 4103: Self-Piercing Riveting
- 1. TALAT Lecture 4103 Self-Piercing Riveting 8 pages, 7 figures Basic Level prepared by Lothar Budde, UniversitĂ€t-Gesamthochschule Paderborn Objectives: â to describe the processes of self-piercing riveting, which is a relatively new fastening method for sheet metal parts Prerequisites: â General mechanical engineering background â TALAT Lecture 4101 Date of Issue: 1994 ïŁ© EAA - European Aluminium Association
- 2. 4103 Self-Piercing Riveting Table of Contents 4103 Self-Piercing Riveting .....................................................................................2 4103.01 Definition and Classification.................................................................... 3 Definition of Indirect Self-Piercing Riveting...........................................................3 Trade Names for Indirect Self-Piercing Riveting Processes....................................3 4103.02 The Riveting Process................................................................................. 4 Form of a Joining Element During Indirect and Direct Self-Piercing Riveting.......4 Process Steps for Self-Piercing Riveting with a Half-Hollow Rivet .......................5 Process Steps for Self-Piercing Riveting with Solid Rivets ....................................6 Different Forms of Joints during Self-Piercing Riveting with Solid Rivets ............6 A Comparison of the Fields of Application of Fastening Technologies..................7 4103.03 Literature/References ............................................................................... 8 4103.04 List of Figures.............................................................................................. 8 TALAT 4103 2
- 3. 4103.01 Definition and Classification âą Definition of indirect self-piercing riveting âą Trade names for indirect self-piercing riveting processes Definition of Indirect Self-Piercing Riveting Among the mechanical fastening methods using auxiliary joining elements, self-piercing riveting appears to be most promising for fastening aluminium because of its estimated development potential. In lieu of the nonexistent standard definition, self-piercing riveting can be classified as a process in which the prior formation of holes, necessary for conventional riveting processes, becomes unnecessary and is replaced by a combined cutting-riveting operation. Depending on the type of rivet used (half-hollow or solid), two principle types of fastening technologies are being used industrially (Figure 4103.01.01). With Half-Hollow Rivets Self-Piercing Riveting is a direct method of forming joints in sheet, tube and profile materials without preformed holes using single piece auxiliary parts (half-hollow or solid rivets) which act as punches With for this purpose. Solid Rivets Source: Budde alu Definition of Self-Piercing Riveting 4103.01.01 Training in Aluminium Application Technologies Trade Names for Indirect Self-Piercing Riveting Processes The individual self-piercing riveting systems with half-hollow and solid rivers are, as in the case of clinching systems, better known and used under their trade names (see Figure 4103.01.02). The fact that in self-piercing riveting the individual joining problems have to be solved by the proper choice of rivets and riveting tool is a source of problems. Consequently, a close cooperation between user and system producer is essential in TALAT 4103 3
- 4. order to arrive at the best fastening results. This is also valid for single-step clinching, with or without local incision. Self-Piercing Riveting * with Half-Hollow Rivets with Solid Rivets - "RIV-SET"-System - "TURK-RIVET"-System - "VTS"-System - "FAS-NER"-System - "S&D RIVET"-System - ................................. - "FAST-RIV"-System - ................................. - ................................. - ................................. * Source: DIN 8593, Part 5 alu Trade Names for Self-Piercing Riveting Processes 4103.01.02 Training in Aluminium Application Technologies 4103.02 The Riveting Process âą Form of a joining element during indirect and direct self-piercing riveting âą Process steps of self-piercing riveting with a half-hollow rivet âą Process steps for self-piercing riveting with solid rivets âą A comparison of the fields of application of fastening technologies Form of a Joining Element During Indirect and Direct Self-Piercing Riveting Besides the indirect punch riveted joints described here, self-punching joining parts, i.e., punch nuts and punch bolts, have also been developed and sold in recent years. In direct self-piercing riveting, the rivet part of the bolt is pierced through the metal sheet. The further closing motion of the tool, together with the specially shaped counter die, causes the rivet head to be formed in such a manner that the pierced sheet is covered over in the joining region (Figure 4103.02.01). TALAT 4103 4
- 5. Indirect Self-Piercing Riveting Direct Self-Piercing Riveting Additionally Introduced Punch Bolt Punch Rivet Sheet Parts Punch Patches Source: Budde, Lappe Form of a Joining Element During alu Indirect and Direct Self-Piercing Riveting 4103.02.01 Training in Aluminium Application Technologies Process Steps for Self-Piercing Riveting with a Half-Hollow Rivet During self-piercing riveting with half-hollow rivets, the rivet is forced to pierce through the punch-side sheet and while penetrating the die-side sheet it is caused by the special form of the die to be plastically formed and forced sidewards into this sheet. The rivet collar thus created in the plastically formed material acts as the closing head (Figure 4103.02.02). Just as in the case of conventional riveting, different head forms are used for simple and complex components and for varying loads. The rivet elements can be stored in magazines or supplied directly. The rivets can be protected against corrosion by surface coating, whereby almost all known coating methods in trommels or drums may be used. Currently, chromated and galvanised steel rivets are generally used for punch riveting aluminium. Connected Parts: Aluminium Half-Hollow Rivet: Galvanised, Chromated steel Half-Hollow Rivet Punch Parts to be joined Rivet Punch Punched out Material Source: Budde, Lappe Process Steps of Self-Piercing Riveting alu 4103.02.02 Training in Aluminium Application Technologies with a Half-Hollow Rivet TALAT 4103 5
- 6. Process Steps for Self-Piercing Riveting with Solid Rivets During self-piercing riveting with solid rivets, the rivet sits flush with the sheet and retains its original geometrical form almost fully (Figure 4103.02.03). The parts of the sheet punched out during the punch process do not remain in the hollow shaft as in punch riveting with half-hollow rivets but have instead to be removed. Thus, the tools used must have an arrangement for allowing the punched out parts to be removed. Connected Parts: Aluminium Solid Rivet: Galvanised, Chromated Steel Punch Solid Rivet Parts to be joined Rivet Anvil Punched out Material Source: Budde, Lappe alu Process Steps for Self-Piercing Riveting Training in Aluminium Application Technologies with a Solid Rivet 4103.02.03 Different Forms of Joints during Self-Piercing Riveting with Solid Rivets Two variations of self-piercing riveting with solid rivets are used industrially to produce quasi form locked rivet joints (see Figure 4103.02.04). During the continuous fastening process, the material in the region of the cut joint is either forced to flow around the rivet plastically due to the action of shoulders on the punch and die or the punch-side rivet is held while a shoulder in the die causes the material of the lower sheet to flow into a groove in the rivet shaft. TALAT 4103 6
- 7. Concave Solid Rivet Solid Rivet with Countersunk without Countersunk Head Head and Grooved Shaft Punch Joining Parts Rivet Anvil Source: Budde, Lappe Different Forms of Joints During Self-Piercing Riveting alu 4103.02.04 Training in Aluminium Application Technologies with Solid Rivets A Comparison of the Fields of Application of Fastening Technologies Mechanical fastening methods for stressed and/or non-stressed aluminium joints are used in a wide range of applications (Figure 4103.02.05). The initial impulse for the use of mechanical fastening methods in the aluminium manufacturing industry came, as it still does, from the aircraft and the automotive industry. A Comparison of the Fields of Application of Fastening Technologies Joining Technology Adhesive Spot Welding Clinching Riveting Joining Characteristic Application single, small single, small single, small single, small large series large series large series large series production production production production Light structures Light structures Light structures Light structures machine constr. machine constr. machine constr. machine constr. electrical engg. electrical engg. building repair repair stressed and stressed and stressed and stressed and unstressed unstressed unstressed unstressed joints joints joints joints Source: Budde A Comparison of the Fields of Application of alu 4103.02.05 Training in Aluminium Application Technolog ies Fastening Technologies TALAT 4103 7
- 8. 4103.03 Literature/References 1. Hoffer, K. Systemoptimierte Verbindungen im Flugzeugbau.VDI-Berichte 360, 31- 43 2. Budde, L. Nietalternativen. Angewandte Technik (1991) 2, 34-40 3. Budde, L. und Lappe, W. Stanznieten ist zukunftstrĂ€chtig in der Blechverarbeitung. BĂ€nder Bleche Rohre 32 (1991) 5, 94-100 4. Budde, L. QualitĂ€tssicherung beim Nieten - Möglichkeiten und Grenzen. BĂ€nder Bleche Rohre 32 (1991) 10, 64-74 5. Stoewer, U.-H. Nietverarbeitung. Angewandte Technik (1991) 2, 22-30 6. Lappe, W. und Liebrecht, F. Grundlegende Untersuchungen zur Eignung des Stanznietens zum Verbinden von Aluminiumwerkstoffen. AbschluĂbericht zum EFB-AIF-Forschungsvorhaben Nr. 2 D, 1993 4103.04 List of Figures Figure No. Figure Title (Overhead) 4103.01.01 Definition of Self-Piercing Riveting 4103.01.02 Trade Names for Self-Piercing Riveting Processes 4103.02.01 Form of a Joining Element during Indirect and Direct Self-Piercing Riveting 4103.02.02 Process Steps for Self-Piercing Riveting with a Half-Hollow Rivet 4103.02.03 Process Steps for Self-Piercing Riveting of a Solid Rivet 4103.02.04 Different Forms of Joints during Self-Piercing Riveting with Solid Rivets 4103.02.05 A Comparison of the Fields of Application of Fastening Technologies TALAT 4103 8