Robust Scaling of Roller Clinching Processes

滚子铆接工艺的稳健扩展

• 批准号: 323223081
• 负责人: Professor Dr.-Ing. Wolfram Volk
• 金额: --
• 依托单位: Lehrstuhl für Umformtechnik und Gießereiwesen
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2016
• 资助国家: 德国
• 起止时间: 2015-12-31 至 2018-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/323223081?language=en
• 关键词: Robust; Scaling; Roller; Clinching; Processes

Compared to processes using stroke movements, manufacturing processes with rotational tool movements offer many benefits, especially for processing semi-finished coil products. Roller clinching uses these positive characteristics and enables a continuous joining process while maintaining high speed.In the first two funding periods of the SPP 1640, experiments were carried out using roller clinching and hole roller clinching. The first phase focused on the basic feasibility of clinching using rotational tool movement. In the second funding period, the range of applications for roller clinching was extended. Using a prehole offers the ability to join materials, which are difficult to form, with well formable materials. Hole roller clinching makes it possible to join hybrid materials, which are important for lightweight design, with rotational tool movement. However, the studies were carried out within very narrow parameter limits, which are specified through the existing roller clinching setup. To gain a complete understanding of the process and to extend the range of use, transferring the results to different dimensions is necessary. So far, no studies extending the given process limits have been conducted. There is also a lack of studies about the robustness of the process, which is directly linked to the scaling of the process due to the special kinematics. Based on the results of previous projects, the focus will now be placed in particular on the scalability and robustness of the joining process. The objective of the project is to expand the process window regarding different application areas. Based on a comprehensive analysis of the kinematic conditions in roller clinching, the effects of scaling the process with regard to the thickness of the sheet material, the relative sizes of the tool rolls and the joining speed are studied using finite element simulations. In addition, robust and technically feasible parameter ranges are elaborated. To validate the results and assess the mechanical properties of the joint, a test stand is designed and constructed. Because of the conducted research, an extension of the application spectrum of the joining method is possible. Thus, roller clinching can be used e.g. to integrate functional electronic components directly in profile parts.

与使用冲程运动的工艺相比，旋转刀具运动的制造工艺具有许多优点，尤其是对于加工半成品卷材产品。在SPP 1640的前两个资助期，使用辊压和孔式辊压进行了试验。第一阶段的重点是使用旋转工具移动的基本可行性。在第二个资助期，扩大了滚压的应用范围。使用预制孔可以将难以成形的材料与成形良好的材料连接在一起。孔辊紧固使混杂材料与旋转刀具运动结合成为可能，混杂材料对于轻量化设计非常重要。然而，这些研究是在非常狭窄的参数范围内进行的，这些参数是通过现有的轧辊咬合装置指定的。为了全面了解这一过程并扩大使用范围，有必要将结果转换到不同的维度。到目前为止，还没有进行延长给定工艺限制的研究。由于其特殊的运动学特性，对过程的稳健性也缺乏研究，这与过程的尺度直接相关。根据以往项目的结果，现在将特别关注加入进程的可扩展性和稳健性。该项目的目标是针对不同的应用领域扩大工艺窗口。在对滚压过程的运动条件进行综合分析的基础上，利用有限元模拟方法研究了滚压过程中板材厚度、刀辊相对尺寸和连接速度等因素对滚压过程的影响。此外，还阐述了稳健性和技术上可行的参数范围。为了验证计算结果和评估节点的力学性能，设计并建造了试验台。由于所进行的研究，有可能扩大连接方法的应用范围。因此，滚压可用于将功能电子元件直接集成在型材零件中。