optimizing the clinched fastener/ clinched component ... · 1 rifast - one system every possibility...
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RIFAST - One System every Possibility © RIFAST LLC April 2014
Optimizing the Clinched Fastener/Clinched Component Design and Interface
to Meet Required Reduced Mass Applications
Viral Varshney
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RIFAST - One System every Possibility © RIFAST LLC April 2014
Who is Rifast Systems, LLC ? Rifast Systems, LLC is your complete source for clinching solutions.
§ Clinching Products
§ Engineering Experience Providing Customer Solutions
§ Applications Lab
§ In die/off Line Installation Equipment
§ Service and Training
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RIFAST - One System every Possibility © RIFAST LLC April 2014
Vehicle Lightweighting – Our Role
Customer Needs
Other Products
Solutions Exist - Why duplicate efforts
Solutions Required - Focus of development
Develop clinching fasteners & installation equipment to support customer applications
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RIFAST - One System every Possibility © RIFAST LLC April 2014
EVOLVE
TEST
LEARN
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RIFAST - One System every Possibility © RIFAST LLC April 2014
Example – Audi Q7 Door Panel Application Information:- Sheet Metal 1.2 mm Al 6061-
T6
# of attachment point 22 Previous fastener Wt. 4.53 g
Total Fastener Weight
99.7 g per door
Total Fastener Weight
0.4 kg. (0.88 lbs) per vehicle
Joint Performance Requirement:- Push Out Force > 400 N Break Loose Torque > 7N.m
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RIFAST - One System every Possibility © RIFAST LLC April 2014
Evolve – LBM (Light Weight Nut)
Product characteristic
Current fastener
Requirement Result
Outer Diameter Ø 14 mm < Ø 14 mm Ø 8.5 mm
Weight 4.53 g < 4.53 g 1.50 g
Push Out Force > 3,300 N > 400 N 930 N
Breakloose Torque
> 40 Nm > 7 Nm 9.5 Nm
Element LBM M5
Material Steel
Weight 1.5 g
Internal Thread Metric M5 6H
Thread Engagement 0.8 x D
Property Class Class 10
Material Range 1 – 5mm
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RIFAST - One System every Possibility © RIFAST LLC April 2014
Result –Audi Q7 Door Panel
Sheet Metal 1.2 mm Al 5083-H32 WEIGHT SAVED
# of attachment point 22 Fastener Wt. 4.53 g 1.50 g 3.03 g
Fastener Weight per door 99.7 g 33 g 66.7 g
Total Fastener Weight per vehicle 0.4 kg. (0.88 lbs) 0.13 kg. (0.29 lbs) 270 g (0.59 lbs)
67% Weight Reduction in
Fastening Elements
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RIFAST - One System every Possibility © RIFAST LLC April 2014
Learn – Window Regulator assembly review
Regulator Pulley
Window Track
Attachment point to door
Extra Material (Opportunity)
Can we reduce attachment points? If yes, we can remove excess material at these locations and reduce weight
Application Information:- Sheet Metal 1.0 mm Al 5083
1.4 mm Al 5083 1.0 mm Cold Rolled Steel
# of attachment point 2 Previous fastener Wt. 43 g Previous Assembly Wt. 144 g
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RIFAST - One System every Possibility © RIFAST LLC April 2014
Evolve – M6 Special EPB Element Special
EPB M6 Material Steel
Weight 13.8 g
External Thread Metric M6 6H
Property Class Class 9.8
Material Range 1 – 2.5 mm
• Integrated the attachment point fastener with the pulley spacer.
• Single component solution for pulley support and door rail attachment
• Two components reduced
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RIFAST - One System every Possibility © RIFAST LLC April 2014
Test – Application testing and results
Sheet Metal 1.4 mm Al 5083 WEIGHT SAVED
# of attachment point 2 Fastener Wt. 43 g 27 g 16 g
Assembly weight per door 144 g 126 g 18 g
Total Assembly Weight per vehicle 576 g 504 g 72 g
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RIFAST - One System every Possibility © RIFAST LLC April 2014
Thank You