EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 1 Fastening Technique for Hybrid Auto Body Structures Ralf Birkelbach, EJOT GmbH & Co. KG
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 1
Fastening Technique for Hybrid Auto Body Structures
Ralf Birkelbach, EJOT GmbH & Co. KG
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 2
Design and material changes in automotive industry
Joining requirement specification
Basic fastener development:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
Content
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 3
Design and material changes in automotive industry
Joining requirement specification
Basic fastener development:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
Content
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 4
Quelle: Cluster „Neue Werkstoffe in Bayern“ 2006
SteelAluminumGlassPlasticsOthers
Design and material changes in automotive industry
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 5
Structure Steel
Hang- ons Steel
Structur Steel
Hang- ons AlStructure Steel
plate parts Al
Hang- ons Al
Al- Die castAl- Extruded profileAl- SheetSt – High strength (22MnB5)
Structure Al/Steel
plate parts Al
Hang- ons Al
Various stages of light weight design in the body in white structure
Source: AUDI AG
Design and material changes in automotive industry
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 6
Design and material changes in automotive industry
Joining requirement specification
Basic developments:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
Content
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 7
Joining different materials together (with minimized preparation)
Solutions for fixing, attachement and structural (high strength) joints
Assembly with and without adhesive between the layers
One side access for fixing into aluminum extrusions (e. g. Space-frame-design)
Accurate assembly without distortion
High dynamic resistance
Crash safety
Fully automated assembly process
High reliability / process control
Multi layer applications
Joining Requirement Specification
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 8
Design and material changes in automotive industry
Joining requirement specification
Basic fastener development:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
Content
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 9
FDS® screw design
Head with recess inside / outside
Usable thread length
Thread forming part
Flowdrilling section
Point (tip) of the screw
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 10
Stages of the FDS® assembly
1. Warming up the sheetmetal by axial end load and high speed
2. Penetration into the material
3. Forming of the extrusion
4. Chipless forming of afemale machine thread
5. Installation
6. Tightening with the pre-set torque
2.1. 3.
4. 5. 6.
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 11
Torque plot of an FDS® joint
1. Forming of the extrusion2. Thread forming 3. Engagement of full threads4. Tightening
Ti = installation Torque
TT = tightening Torque
TS = stripping Torque
torq
ue (N
m)
time (sec.)
1.2.
3.
4.Ti
TT
Ts
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 12
System for fullautomated FDS Robot-assembly (left) and feeding system (right)
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 13
Fully automated FDS® assembly (with clearance hole)
n: speedM: torqueF: endload
2.1. 3.4. 5. 6.
Finding Warm up Draft forming Thread forming Drive in Tightening
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 14
EN AW-5754 t=1,15 mm
EN AW-6082-T6 t=3.2 mm
FDS® Example in Aluminum (with clearance hole)
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 15
Design and material changes in automotive industry
Joining requirement specification
Basic developments:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
Content
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 16
Series Applications with Selfpiercing and Extruding Screws
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 17
Application examples (with clearance hole)Lamborghini Gallardo: fully automated assembly at Thyssen Krupp Drautz
• Fixation of the base plate (1 mm) onto Aluminum body frame (3 mm)
• 160 FDS® M5 x 18 without pilot hole
source: Audi AG
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 18
Assembly of 100 FDS® M5x18 screws without pilot hole into:
• Aluminium profile with thicknesses:- 1,25mm EN AW-6181-A T4- 1,5mm EN AW-6181-A T4- 2,0mm EN AW-6063 T6- 3,9mm EN AW-6063 T6
Clamped part:• Aluminium die-cast material
- 2mm C611 T5with 7mm clearance hole
Application examples (with clearance hole)Ferrari California: assembly of the tunnel
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 19
Application examples (with clearance hole)Audi TT Coupe/Roadster: fully automated robot assembly in the „body in white“ production
Robot-assembly (12 systems) for 229 FDS® M5 screws (255 for Roadster) without pilot hole into:
• Aluminium profile: thickness 1,5 up to 3,5mm
• Aluminium die-cast material up to 3mm• Clearance hole diam.: 7mm• 80% of the FDS assembly into
aluminium profile• 75% in combination with adhesive
(no adhesive in the clearance hole)
source: Audi AG
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 20
Application examples (with clearance hole)Audi TT Coupe/Roadster:fully automated robot assembly in the „body in white“ productionMaterial– mix assembly
Steel plate 1,2 mm on aluminium profile 2,5 mm
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 21
Application examples (with clearance hole)Audi TT Coupe/Roadster:fully automated robot assembly in the „body in white“ production
Fixation of aluminium sheet 1,15mm on
- 1,5 mm aluminium frame rail
- 3 mm aluminium die-cast
- 2 mm aluminium cross beam
with different tightening torques
Fixation of car body shell 1,15 mm on
aluminium die-cast 3 mm
A-pillar
Demo Video
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 22
Design and material changes in automotive industry
Joining requirement specification
Basic developments:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
Content
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 23
Further optimized FDS® screw design
Head with recess outside / inside
Usable thread length
Thread forming part
Flowdrilling section
Point (tip) of the screw
Increased underhead bulge
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 24
4. 5. 6.
Heating PenetratingExtrusion forming
Thread forming
= Downholder
Engagement of full threads Tightening
2.1. 3.
Process steps of FDS® assembly without part preparation
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 25
Assembly principlesMaterial combination and downholder design for assembly without clearance hole
Note:
Preferred material combination:
• „Thin“ on „Thick“ and/or.
• „weak“ on „hard“
Adjustable downholder force
Fastening direction
Clamped part (without clearence hole)
Installation part
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 26
Fully automated FDS® assembly (without holes)
n: speedM: torqueF: endload
Finding Warm up Draft forming Thread forming Drive in Tightening
2.1. 3.
4. 5. 6.
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 27
EN AW-5754 t=1.5mm
EN AW-6082-T6 t=3.8mm
FDS® Example in Aluminum (without holes)
Demo Video
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 28
Design and material changes in automotive industry
Joining requirement specification
Basic developments:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
Content
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 29
Application examples (without holes)Audi R8: Fully automated robot assembly in the „body in white“ production
Assembly of 310 FDS® M5 screwswithout pilot and clearance holeinto:
• Aluminium profile: thickness 1,5 up to 3,5mm
• Aluminium die-cast:up to 3mm
• Max. clamped part thickness 1,15mm
source: Audi AG
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 30
Application examples (without holes)Audi R8:Fully automated robot assembly in the „body in white“ production
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 31
Application examples (without holes)Audi A8 (D4): FDS® Screw M5x20
Assembly:• Installation parts:
- 1,0 bis 4,8mm Aluminium profile- 2,5 bis 3,5mm Aluminium die-cast
• Clamped parts:- Aluminium (with and mostly without
clearance hole)
• 740 FDS® M5 x 20 (per car)
• 18 joints as 3-layers
source: Audi AG
Fully automated robot assembly in the „body in white“ production
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 32
Preferred conditions:
• clamped part thickness <= installation part thickness
• clamped part thickness max. 30% higher than underhead bulge
• clamped part hardness <= installation part hardness
• max. tensile strength installation part: ~ 800 MPa
Advantages:
• no hole operation at all
• no consideration of tolerances
• structure fixing with or without adhesive
• one side access assembly
Disadvantage:
• special headstyle required
• screw more expensive than with ordinary headsytle
Guideline and recommendations
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 33
Design and material changes in automotive industry
Joining requirement specification
Basic developments:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
Content
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 34
Multi layer FDS® screw design
Head with recess outside / inside
Usable thread length
Thread forming part
Flowdrilling section
Point (tip) of the screw
Increased underhead buldge
Calibration part
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 35
FDS M5x25
• Installation part: HC 340 LA (2mm)
• Clamped part 1: Aluminium EN AW-6181 (1,5mm)
• Clamped part 2: Aluminium EN AW-6181 (1,5mm)
Multi-layer application (3-layer Material Mix Aluminum/Steel)
Ti Ts t Process (Nm) (Nm) (sec.) end
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 36
Multi- layer application (3- layer stack-up of Aluminum)
FDS M5x25
• Installation part: Aluminium EN AW-6181 (2,0mm)
• Clamped part 1: Aluminium EN AW-6181 (1,5mm)
• Clamped part 2: Aluminium EN AW-6181 (1,5mm)
Ti Ts t Process (Nm) (Nm) (sec.) end
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 37
Multi- layer application (4- layer stack-up of Aluminum)
FDS M5x25
• Installation part: Aluminium EN AW-6181 (1,5mm)
• Clamped part 1: Aluminium EN AW-6181 (1,5mm)
• Clamped part 2: Aluminium EN AW-6181 (1,5mm)
• Clamped part 3: Aluminium EN AW-6181 (1,5mm)
Ti Ts t Process (Nm) (Nm) (sec.) end
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 38
Multi layer FDS® screw design
Head with recess outside / inside
Usable thread length
Thread forming part
Flowdrilling section
Point (tip) of the screw
Increased underhead buldge
Calibration part
Can and is also being used for the 2 layer joints
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 39
Joining different materials together
Solutions for fixing, attachement and structural joints
Assembly with and without adhesive between the layers
One side access for fixing into aluminum extrusions (e. g. Space-frame-design)
Accurate assembly without distortion
High dynamic resistance
Crash safety
Fully automated assembly process
High reliability / process control
Multi layer applications
Fulfillment of Joining Requirement Specification
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach Folie 40
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