Robust Scaling of Roller Clinching Processes

与使用冲程运动的工艺相比，使用旋转工具运动的制造工艺提供了许多优点，特别是对于加工半成品线圈产品。滚柱铆接利用了这些优点，能够在保持高速的同时实现连续的连接过程。在SPP 1640的前两个资助期内，进行了滚柱铆接和孔滚柱铆接的实验。第一阶段的重点是使用旋转工具运动的铆接的基本可行性。在第二个资助期内，扩大了滚柱铆接的申请范围。使用预孔提供了将难以成形的材料与可良好成形的材料接合的能力。孔辊压接可以通过旋转工具运动连接混合材料，这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限制内进行的，这些参数限制是通过现有的辊压接设置指定的。为了全面了解过程并扩大使用范围，将结果转移到不同的维度是必要的。到目前为止，尚未进行任何研究来扩展给定的工艺限度。也有一个缺乏研究的鲁棒性的过程，这是直接联系到缩放的过程中，由于特殊的运动学。根据以前项目的结果，现在的重点将特别放在加入过程的可扩展性和鲁棒性上。该项目的目标是扩大不同应用领域的进程窗口。在全面分析辊压成形运动学条件的基础上，利用有限元模拟研究了板材厚度、工具辊相对尺寸和连接速度对辊压成形过程的影响。此外，阐述了稳健和技术上可行的参数范围。为了验证结果和评估接头的力学性能，设计和建造了一个试验台。由于所进行的研究，连接方法的应用范围的扩展是可能的。因此，滚柱铆接可以用于例如将功能性电子部件直接集成到型材部件中。

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.