GALM PRESENTATION - LBCG · HENROB –IN BIW / CIW Complexity of Henrob Self-Pierce Riveting (HSPR)...
Transcript of GALM PRESENTATION - LBCG · HENROB –IN BIW / CIW Complexity of Henrob Self-Pierce Riveting (HSPR)...
GALM PRESENTATIONREVIEWING THE COMPLEXITY OF HENROB SELF-PIERCE
RIVETING (HSPR) APPLICATIONS IN BIW / CIW TO
UNDERSTAND ITS FULL CAPACITY
April 14, 2015
HENROB – WHAT WE DO
Our sole focus is Self-piercing Rivets (SPR) and Self-piercing
Riveting Systems
Innovative Joining Solutions
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HENROB – IN BIW / CIW TRENDS
Complexity of Henrob Self-Pierce Riveting (HSPR)
AL Sheet
AL Casting
AL Extrusion
AL Sheet
AL Casting
AL Extrusion
HSS Steel
PHS Steel
AL Sheet
AL Casting
AL Extrusion
HSS Steel
PHS Steel
Mg Casting
Composites
15-years ago 5-years ago 5-years from now
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2T Joint
Steel to steel
Aluminum to aluminum
Multiple Joint
Aluminum alloys
Up to 10 mm
Mild Steel alloys
Up to 6 mm
Dissimilar
Metals
Aluminum to steel
to aluminum
Dissimilar
Materials
Plastic / aluminum
3mm extrusion
+ gasket
+ 2mm HS steel
HENROB – IN BIW / CIW
Complexity of Henrob Self-Pierce Riveting (HSPR)
Quiet Steel
1mm + steel laminate
+ 3mm with Adhesive
reduces NVH
3mm + 3mm + 2.7mm
3T Aluminum with
Adhesive
Self Piercing Stud
M6 SPS in 2.3 mm
.9mm + 1.2mm
+ 2mm Aluminum
to Aluminum to
Mild Steel
.9mm +2mm + 2.7mm
3T Aluminum with Adhesive
.9mm + 3mm + 3.2mm
3T Aluminum with
Adhesive
T-Rivet geometry increases
bore depth allowing for a longer
rivet and increased interlock
FAQS
Rivet weight per AIV BIW
SPR Cycle time vs. RSW Aluminum
SPR Fatigue strength and properties
Surface prep requirements
Galvanic reaction with Steel/Aluminum
Non-Destructive-Testing (NDT)
Energy consumption
Aftermarket sustainability
WHAT IS HENROB SPR
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Innovative Joining Solution for aluminum and mixed
material applications
The Process
Rivet pierces upper sheet
material
Rivet flares into lower material but
does not break through
Rivet head clamps down tightly onto
top material
WHAT IS HENROB SPR
WHAT'S CRITICAL TO AN SPR JOINT
Early Engagement – Is Key
Preferred - Thin to Thick
Bottom sheet is >33% of the TOTAL stack
Better strength consistency
Easier rivet rationalization
Less chance of rivet tail breakthrough
Non-Preferred - Thick to Thin
Bottom sheet is <33% of the TOTAL stack
Lower strength consistency
Difficult rivet rationalization
Increased chance of rivet tail breakthrough
Basic Design Rule
WHAT'S CRITICAL TO AN SPR JOINT
Resources to support CAE &
Modeling
Early Engagement – Is Key for Joint Development testing
Riveted “coupons” are made using the application materials to test joint strength and integrity.
WHAT'S CRITICAL TO AN SPR JOINT
WHAT'S CRITICAL TO AN SPR JOINT
Required Process Inputs – Tooling
• What product parts will be present in cell
• Identify spots each tool will be riveting
• Correlate the spot numbers to the Joint
Identification (JID) numbers
• Section the parts though the rivet
centerline and stack all the joints together
to define the total access requirements
• Develop part holding/locating
requirements to assess gun access
Rivet Setter
Rivet Spool
Die PostFeedSystem
C-Frame
Robot Mount
Early Engagement – Is Key
LESSONS
Early engagement with vendors is critical with AIV development
Manufacturing strategy aligned with product development
Reduce learning curve utilizing vendors with previous experience
Early testing and validation is key to success
Eliminate changes or organize and manage the change process
Quality and operational issues can be negated with early adoption
of new technology standards and procedures
Utilize vendor resources at every level of product design cycle
through launch