Investigation of versatile joining processes for the manufacturing of hybrid components in an industrial environment (T01#)

该项目的范围是在跨区域合作研究中心TRR （SFB/TRR）“工业条件下多功能工艺链机械连接方法开发”的背景下，在“紧固件多功能连接”子项目中，分析所调查方法的可转移性，以实现翻转自穿孔铆接工艺的多功能性。在这种情况下，这种多功能性应该通过针对目标的相关工艺参数的调整来扩大。本研究项目的中心目标是将基本结果转化为确定几何连接特征的形成，例如从翻滚自穿铆接工艺到轨道成形工艺的新型连接。在SFB/TRR中，从根本上研究了机械连接工艺和工艺链的多功能性的科学方法。这些结果应该应用和转移到工业相关的问题，如连接过程以及组件设计。在子项目范围内，将已建立的自穿孔铆接工艺与轨道成形工艺相结合，进行了基本研究，并评估了提高通用性的技术潜力。在这种情况下，翻滚运动学、翻滚角度以及连接伙伴的选择对凹口的形成和铆钉头端位置产生重大影响，从而影响连接质量。然而，限制因素阻碍了可能的工业应用。由于使用额外的紧固件，除了增加处理工作外，连接方向是一个相当大的问题。此外，在钣金平面上有接头的零件不能制造。因此，翻滚自穿铆接过程中几何连接形成的基本发现应该与相关合作伙伴SRAM Deutschland GmbH和C.D. Wälzholz GmbH & Co. KG密切合作，转移到一种新的连接技术上，完全由轨道成形步骤组成，不需要额外的紧固件，在工业方面。除了使用与工业相关的材料类别外，还应建立对新型通用连接工艺的基本工艺理解，并对可能的后续应用进行评估。通过对本项目中确定的相关工艺参数的明确调整，应该为这种新的通用工艺的可能应用奠定基础。双方在半成品、材料、应用、要求和质量评估方面都有具体的专业知识，因此对转移项目的成功做出了重大贡献。

The scope of the project is the analysis of the transferability of the investigated methodology for the versatility of a tumbling self-piercing riveting process within the subproject "Versatile joining with a fastener" in the context of the transregional collaborative research center TRR (SFB/TRR) "Method development for mechanical joinability in versatile process chains" under industrial conditions. Within this context, this versatility should be expanded by target-oriented adaption of relevant process parameters. Central aim within this research project is the transfer of fundamental results for a defined formation of geometrical joint characteristics, like for example undercuts from the tumbling self-piercing riveting process to a novel joining by orbital forming process. Within the SFB/TRR, scientific methods for the versatility of mechanical joining processes and process chains are investigated fundamentally. These results should be applied and transferred onto industrial relevant questions regarding the joining process as well as the component design. The established joining process of self-piercing riveting is combined with an orbital forming process and investigated fundamentally in the scope of the subproject and the technological potential for an increased versatility is evaluated. In this context, the tumbling kinematic, the tumbling angle as well as the chosen joining partners could be identified as significant influence on the forming of undercuts and the rivet head end position and in consequence on the joint quality. Nevertheless, limiting factors prevent a possible industrial application. Due to the use of an additional fastener, the joining direction is a considerable issue besides the increased handling effort. Furthermore, parts with a joint in the sheet metal plane cannot be manufactured. Therefore, the fundamental findings on the geometrical joint formation within the tumbling self-piercing riveting process should be transferred in close cooperation with the involved partners SRAM Deutschland GmbH and C.D. Wälzholz GmbH & Co. KG onto a new joining technique, exclusively consisting of an orbital forming step without additional fastener, under industrial aspects. Besides the use of industrial relevant material classes, a fundamental process understanding of the novel, versatile joining process regarding the occurring interdependencies should be established and a possible later application should be evaluated. By a defined adaption of relevant process parameters, identified in this project, the foundation for a possible application of this new versatile process should be placed. Both partners participate with specific know-how on semi-finished products, material, application, requirements and the evaluation of quality and consequently contributing significantly to the success of the transfer project.