Robust Scaling of Roller Clinching Processes

与使用冲程运动的过程相比，使用旋转工具运动的制造过程提供了许多好处，特别是对于加工半成品线圈产品。辊夹紧利用这些积极的特点，使连续连接过程，同时保持高速。在spp1640项目的前两个资助期内，分别进行了滚轮夹持和孔滚轮夹持的实验。第一阶段重点研究了刀具旋转夹持的基本可行性。在第二个资助期内，滚子夹持的应用范围扩大了。使用预孔可以将难以成形的材料与成形良好的材料结合起来。孔滚子夹紧使得混合材料的连接成为可能，这对于轻量化设计非常重要，并且可以通过旋转工具运动来实现。然而，研究是在非常狭窄的参数范围内进行的，这是通过现有的滚子夹持设置指定的。为了完全理解这个过程并扩展使用范围，将结果转移到不同的维度是必要的。到目前为止，还没有进行任何延长给定工艺限制的研究。对于该过程的鲁棒性研究也较少，这直接关系到该过程由于特殊的运动学特性而产生的尺度化。基于以前项目的结果，现在的重点将特别放在连接过程的可扩展性和健壮性上。该项目的目标是扩展关于不同应用领域的过程窗口。在全面分析滚子夹紧运动条件的基础上，采用有限元模拟方法研究了夹紧工艺对板材厚度、刀辊相对尺寸和连接速度的影响。此外，还阐述了鲁棒性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，设计并建造了一个试验台。通过对该方法的研究，使其应用范围的扩大成为可能。因此，可以使用滚子夹持，例如将功能电子元件直接集成到型材零件中。

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.