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.

与使用中风运动的过程相比，带有旋转工具运动的制造工艺提供了许多好处，尤其是用于处理半成型的线圈产品。滚子弯曲使用这些积极特征，并在保持高速的同时进行连续的连接过程。在SPP 1640的前两个融资期间，使用滚筒弯头和孔滚筒弯头进行了实验。第一阶段的重点是使用旋转工具运动的基本可行性。在第二个融资期间，延长了滚子弯曲的应用范围。使用预孔具有连接材料的能力，这些材料很难用良好的材料形成。孔辊弯曲使得与旋转工具运动的混合材料相结合，这对于轻质设计很重要。但是，研究是在非常狭窄的参数限制内进行的，这些参数限制是通过现有辊式夹紧设置指定的。为了完全了解该过程并扩展使用范围，必须将结果传输到不同的维度。到目前为止，还没有进行扩大给定过程限制的研究。关于该过程的鲁棒性，还缺乏研究，这与由于特殊运动学而导致的过程的缩放直接相关。根据先前项目的结果，现在将焦点特别放在加入过程的可扩展性和鲁棒性上。该项目的目的是扩展有关不同应用领域的过程窗口。基于对滚子弯曲中运动学条件的全面分析，使用有限元仿真研究了对板材材料厚度的缩放量表的效果。另外，详细阐述了鲁棒和技术可行的参数范围。为了验证结果并评估关节的机械性能，设计和构建了一个测试架。由于进行了研究，因此可以扩展加入方法的应用谱。因此，滚子弯曲可以使用，例如将功能电子组件直接集成到轮廓零件中。