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中机械可连接性的方法开发”的背景下，分析子项目“紧固件的多功能连接”中翻滚自冲铆接工艺多功能性的研究方法的可移植性。在这种情况下，这种多功能性应扩大的目标为导向的调整有关的工艺参数。该研究项目的中心目标是将定义的几何连接特征的基本结果转移到轨道成形过程中，例如从滚转自冲铆接过程中的底切。在SFB/TRR中，从根本上研究了机械连接工艺和工艺链多功能性的科学方法。这些结果应该应用并转移到与连接过程以及组件设计相关的工业问题上。在子项目范围内，将自冲铆接的既定连接工艺与轨道成形工艺相结合，并对其进行了基本研究，并对增加通用性的技术潜力进行了评估。在这种情况下，滚转运动，滚转角度以及所选择的连接伙伴可以被确定为对底切的形成和铆钉头端位置以及因此对接头质量的显著影响。然而，限制因素阻止了可能的工业应用。由于使用了额外的紧固件，除了增加的处理努力之外，连接方向是一个相当大的问题。此外，不能制造在金属板平面中具有接头的零件。因此，滚转自冲铆接工艺中几何连接形成的基本研究成果应与相关合作伙伴SRAM Deutschland GmbH和C.D. Wälzholz GmbH & Co. KG在工业方面致力于一种新的连接技术，该技术仅由轨道成形步骤组成，无需额外的紧固件。除了使用工业相关材料类别外，还应建立对新型通用连接工艺的基本工艺理解，并评估可能的后续应用。通过对本项目中确定的相关工艺参数进行定义调整，为这种新的多功能工艺的可能应用奠定了基础。双方合作伙伴都提供了关于半成品、材料、应用、要求和质量评估的具体专业知识，从而为转让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.