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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
Flexible material joining technology for tomorrow`s innovative lightweight design3
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
Flexible material joining technology for tomorrow`s innovative lightweight design4
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
Flexible material joining technology for tomorrow`s innovative lightweight design5
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
Flexible material joining technology for tomorrow`s innovative lightweight design6
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
Flexible material joining technology for tomorrow`s innovative lightweight design7
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
Flexible material joining technology for tomorrow`s innovative lightweight design8
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
Flexible material joining technology for tomorrow`s innovative lightweight design9
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
Flexible material joining technology for tomorrow`s innovative lightweight design10
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
Flexible material joining technology for tomorrow`s innovative lightweight design11
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
Flexible material joining technology for tomorrow`s innovative lightweight design12
Stiffness simulation
Mises-Spannungen
Process simulation
Good accord with experiment Validation shows agreement with reality Optimization production suitable design
ImpAcT - Simulation results
Flexible material joining technology for tomorrow`s innovative lightweight design13
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
Flexible material joining technology for tomorrow`s innovative lightweight design14
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
Flexible material joining technology for tomorrow`s innovative lightweight design15
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
Flexible material joining technology for tomorrow`s innovative lightweight design16
FLS ImpAcT
Impact - at Mercedes SL- classVideo
ImpulsAccelerated
Tacking
ImpulsAccelerated
Tacking
Flexible material joining technology for tomorrow`s innovative lightweight design17
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
Flexible material joining technology for tomorrow`s innovative lightweight design18
Thank you for your kind attention