global solutions - lbcg€¦ · global solutions . problem: pierce and clinch fastening solution:...
TRANSCRIPT
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North America United Kingdom
Korea Japan
Taiwan China
Germany
Mexico
Australia S. Africa Brazil
Indonesia Thailand
GLOBAL SOLUTIONS
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PROBLEM: PIERCE AND CLINCH
FASTENING
SOLUTION: � Welding complexity � Robust method of
attachment � Torque relaxation � Corrosion � Cost
Lightweight Material Challenges
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Pierce and Clinch Video
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PIERCE and CLINCH BENEFITS
Mass Reduction in Joint
Compact Packaging
Elimination of Secondary Operations
Nut Center to Center
Tolerance 0.2mm
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Shorter nut body = Shorter mating bolt + reduced weight + reduced cost
SPAC nut punch fills parent material
- Smaller Envelope - Shorter nut body - Shorter Bolt - Reduced Weight - Reduced Cost
Packaging Reduction
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SPAC nut punch fills parent material
- Smaller Envelope - Shorter nut body - Shorter Bolt - Reduced Weight - Reduced Cost
Adjacent Material
Packaging Reduction
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LOWER MANUFACTURING COSTS
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HIGH STRENGTH / HOT-STAMPED
MATERIAL TYPES : ¾ Hot Stamped 1300 to 1600 ¾ Cold Rolled 980 Mpa ¾ J 2340 1300-1500 ¾ J 2340 800DL-1300DL ¾ Usibor 1500 ¾ M 190 ¾ MBW 1500 ¾ MBW 1900 ¾ DOCOL 1000/1200
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X-Ray Diffraction Residual Stress Summary
www.rbwmfg.com
• X-Ray Diffraction test was conducted to investigate the pattern and magnitude of the Residual Stresses within “Hot-Stamp Materials.
• Test results from X-Ray Diffraction show that the test coupons were in a state of compression. A compressive state is desirable since cracks cannot be propagated.
• Reference Standards: • ASTM E975-03(Reapproved
2008) • ASTM E915-10
Delayed Fracture Testing Summary
• Delayed Fracture testing was conducted to determine if stress corrosion cracking could initiate micro-cracks in the “Hot-Stamp” material under a fully loaded condition.
• Test results have demonstrated that micro-cracking was not evidenced for various installation methods as governed by referenced test methods and guidelines.
• Reference Standards: • ASTM G39-99( Reapproved 2011) • NACE Standard TM0177 – 2005 Item
No. 1212
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Boron Steel Property Class 10 Joint
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Hot Stamped
• 1300 Mpa tensile strength material • Fastener close to radius • Issues with weld nuts – cold welds &
weld arcing at stamping radius • Micro-crack potential with pre-pierced
or laser cut holes
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More Than Fasteners More Than Ever
RB&W Corporation helping industries keep it together....
Welded solution Nut plate with weld nuts welded to the B Pillar
Self Pierce & Clinch Solution 1. 2 SPAC nuts installed post hot
stamping automatically & simultaneously through 2 layers of material
Usibor 1500 (1.5 & 1.4mm = 2.9mm total thickness)
High Strength Application Business Case
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Boron Hot Stamped Beam
13
Total Length = 1130mm - 1500 Mpa - Pierce and Clinch
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ALUMINUM MATERIAL TYPES: ¾ 6061 - T6 ¾ 5000 Series 90 MPa ¾ 6000 Series 90- 115 MPa ¾ 6063 – T6 ¾ 6111 – T4 ¾ A5023 – H24 ¾ EN-AW 6082 ¾ BG- AlSi 12- 230
RIVNUTS / INSERTS SPAC® NUTS
Locally higher wall thickness is a big problem for die cast tooling
Consistent wall thickness throughout the casting Lower overall height
Extra material is needed to use
threaded inserts.
Cheaper tool design because of straight
walls.
Applications: - Cast Aluminum - Extruded Shapes - Stampings
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Typical Cast Design
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Helicoil in Castings VS. SPAC Nuts in casting
Operations: Casting an Embossment Drilling and tapping Insert Helicoil
Summary: difficult to cast an embossment, many operations needed
Operations: Pierce and clinch into casting up to 10 mm Aluminum
Summary: one operation needed. No added wall thickness necessary
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M10 attachment points
M6 attachment points
M8 attachment points
Aluminum Cast Attachment Points
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Remove embossments and material usage Simpler die design Remove machining and drilling/tapping Overcome material thickness variation
Resulting Enhancements
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Lightweight Material Challenges “Torque Relaxation”
Additional washers / spacers need to be used to increase bearing surface area adding cost + weight + increased length of bolt.
Self pierce & clinch fastener provides a one piece light-weight low profile solution
8
9
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SPAC®PLUG Top Flush with Aluminum Stamping
Multi Material Joining Solution
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SPAC ® PLUG INSERT
Aluminum Stamped Structure
High Strength Steel Stamped Structure Weld Tip
Weld Tip
Joining Aluminum to High Strength Steel
- Create Resistance Spot Weld Point - Utilize existing weld line
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MAGNESIUM
MATERIAL TYPES: ¾ AZ91D ¾ AM 50 ¾ AM 60
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Cast Magnesium with Pierce Nuts
HIGH PERFORMANCE CRITICAL PIERCE NUT PRODUCT APPLICATIONS
JOINT CONSIDERATIONS
• Packaging constraints • Costs and Time to machine
holes • Casting die complexity and
cost for pre hole • Inserting without cracking
material • Corrosion
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FASTENING IN MAGNESIUM GALVANIC PROTECTION
TRADITIONAL FASTENING DESIGN
MAGNESIUM
DISSIMILAR METAL
ALUMINUM SELF PIERCE NUT
ALUMINUM HEX FLANGE BOLT
ALUMINUM PIERCE AND CLINCH NUT DESIGN
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Magnesium Pierce and Clinch Joints
6000 / 7000 Series Aluminum SPAC Nut
Load Monitored Insertion Forces No pre hole Flush Surface
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THANK YOU