tox joining systems - lang & · pdf filestresses around the weld nugget, ... shear and...
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TOX® Joining Systems
TOX® Round JointTOX® Flat JointTOX® Vario JointTOX® SKBTOX® ClinchRivet
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The TOX® Joining SystemsThe best answer to every challenge.
Why a new technique?Because all previous methodshave involved economic and tech-nical problems. Take welding, forexample. A complex, expensiveprocess which can only beapplied to precoated sheet metalor aluminium with great difficulty.Surface coatings are damaged orsheet metals are not joined pro-perly. And there is still no reliableautomatic process control for allthese imponderable factors.
The TOX® joining technique putsan end to these problems. It joinsdifferent materials by means of adeep drawing-pressing process.And it does so without damage tothe surface, purely by displacingand forming.
Practice has alreadyshown the benefits ofTOX®, both technicallyand economically.
Side part of a seat
Sun roof frame
Hand brake lever
Engine mountEngine bonnet Brake disk covering
Home appliances: joining prepaintedsheet metal made possible with TOX®!
PC housings: TOX® preservesthe anticorrosive surface coating.
Kitchen drawer slides:with TOX®, ready for
installation.
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See for yourself:
+ TOX® round joint: 30 to 60percent cost savings as comparedto spot welding.
+ The TOX® joint achieves up to70% of the static strength of aspot weld.
+ The dynamic strength of TOX®
joint is higher than in spot weld-ing.
+ The process can be automaticallymonitored and documented.
+ Simple, non-destructive quality control is possible.
+ The materials are strain hardenedat the connecting joint and aretherefore stronger compared tospot welding, which has significantstresses around the weld nugget,the TOX® joint does not exhibitany metallurgical residual effects.
+ Optimal corrosion resistance withgalvanized and prepaintedmaterials, since the protectivelayer flows with the material.
+ Perfect joints are producedeven with narrow flanges andsmall mounting spaces.
+ Outstanding conductivity forelectric components.
+ Cold forming process is ideal for hybrid connections (gluing and clinching).
+ The TOX® round joint can carryshear and pull stress loads,independent of the load orienta-tion.
+ TOX® ClinchRivetComparable strength to self-piercing rivets but without cutting the sheet metal layers.
Dr. Rudolf Eberle innovation prizefor exemplary achievement.
Seat rail
Window lifter
TOX® advantages for a good connection
For each operation a suitablesolution:
• Point diameter from 2 to 18 mm
• Individual sheet thicknessesfrom 0,2 to 8 mm
• 2 – 4 sheet metal layers
• Composite layers(steel/glue/aluminium)
• Extensive know-how
• World-wide service
How may we help you?
With our TOX® test report weguarantee our technology.
Zinc coated parts:with TOX®, the coa-ting remains intact!
Gas meter housing: TOX® joints are leakproof. Miniature relay contacts:
securely joined withTOX®-Microjoint Ø 2 mm.
4
2
. . . . . . . . . . . .
Einzelblechdicke ts = tm (mm)
Fs
,F
k(N
)
2
. ,
. ,2
. ,
2
. ,
. ,2
. ,
2
. ,
X-M
aß
(mm
)
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TOX®-TechnologyClinching facts
Durability of TOX®
Static strength up to 70% of a spotweld, with positive strain hardening,without damage to the surface coat-ing, and typically more economical.Isn’t all this worth looking at?
The strength behind the TOX®
JointIn the TOX® Round Joint process,the material strain hardening in theneck area and the lacking of anynotch effects produce the highretaining forces. This is the directresult of the fixed, rigid die.
The TOX® ClinchRivet process com-bines the advantages of the RoundJoint with those of a rivetingprocess.
The dynamic strength is higherthan in spot welding.Advantageous dynamic strengthwithout notch effect in the joint - thismeans: the life of the TOX® roundjoint lasts much longer than that of aweld point.
On the right:The TOX® joint in customer testResults of endurance tests for sam-ples with TOX® round joints and spotwelds.The joints were exposed to an initialload of 1 kN and a frequency ofapproximately 35 Hz. The fatigue lifeof the joint was measured until fail-ure.
Test series standard tool set(without tool change)
Fs, Fk (N) X-Dimension (mm)
Surface: as-rolled tp= punch sideMaterial: St 1203 (CRS) td= die side
2,25
2
1,75
1,5
1,25
1
0,75
0,5
0,25
0
4500
4000
3500
3000
2500
2000
1500
1000
500
0
This is how a TOX® Joint isformed
• Penetration• Interlock formation of punch
side sheet metal• Completed TOX® Joint
For
ce a
pmlit
ude
Fa
2000
1500
1000
500
Joined samples, vapour degreasedFD,100%
280 N Spot welding
Clinching, star shape
FD = fatigue strength
TOX® Round Joint
250 N
560 N
103 104 105 106 107 108
Number of cycles NB
20s
F
Source: DFB (German Research Group) research report No. 37
St 1403/s= 0.8 mm
1 2 3 4
9
8
7
6
5
4
3
2
1
0
with ageing1000-hr-salt spray test1000-hr-climate test
1.00 1.25 1.55 1.75 2.15 2.55
Fatigue strength under themost adverse conditions.Corrosion tests have shown thatbecause the surface coating is notdamaged during the round jointprocess, the anti-corrosive propertiesof the joined sheet metals, e.g., alu-minized or galvanized, are main-tained. The TOX® joining system doesnot cut the surface of the materials tobe joined, as the coating flows withthe material and remains intact.
Corrosion testShear forceFs in kN
TOX® Round Joint 6 mm
TOX® ClinchRivetTOX® Round Joint
1 = material = St 1403 (crs)Individual sheet thicknesst = 0.8 mmvapour degreased
2 = material = St 1403 (crs)t = 0.8 mm adhesive film
3 = material = St 1403 (crs)t = 0.8 mm edge-formedseam adhesive paste
4 = material = Al Mg 5 Mnvapour degreased
Cross tension Fk
Dimension X
Shear tension Fs
Single sheet metal thicknesstp = td (mm) ts = tm (mm)
5
2800
2600
2400
2200
2000
1800
1600
1400
1200
1000
450
400
350
300
250
200
150
100
50
0
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160.000
140.000
120.000
100.000
80.000
60.000
40.000
20.000
0
t = < 1,0 t = 1,0 – 1,2 t = 1,3 – 1,5 t = 1,6 – 2,0
normaler Standmengenbereich
Einzelblechdicken (mm)
Anz
ahl F
ügep
unkt
e / S
atz
Werkzeugstandmengen bei EdelstahlBlechwerkstoff: 1.4301 ölig / TOX®-Punkt 8,0 mm
TOX®-TechnologyThe advantage for you and the environment:cost effective and efficient
TOX® Joining: the simple processcuts your manufacturing costs.
The system efficiency and the ser-vice life of the tools are closely inter-dependent.
(1) shows a cost comparison for thesingle joint technique between spotwelding and TOX® joining for a mildsteel application. The TOX® joiningsystem can be used in multipointapplications, which can increaseconsiderably the cost differencebetween TOX® joining and spotwelding.
(2) shows the normal service life ofTOX® tools. The given values andguidelines depend on the particularapplication.
TOX® ClinchRivetThe TOX® ClinchRivet is a logicalfurther development of the TOX®
Round Joint with greater resistancefor crash applications. By filling thejoint with the rivet, the TOX®
ClinchRivet process increases thejoint strength considerably, especial-ly the shear strength. Higherstrength can be achieved whencompared to pierce rivets, especiallywith thin sheet metals. It is importantto mention that with TOX®-ClinchRiv-eting, the upper sheet metal layerwill not be cut: no risk of corrosion.
See data sheet 80.04 for additionalinformation.
TOX® Joining of Stainless SteelStainless steel presents specialrequirements for forming processes.The required higher forming forcesresult in higher surface stresses onthe joining tools. The TOX® JoiningTechnology can be used safely andefficiently even for stainless steelapplications. Continuous tool devel-opment and experience with manyapplications have resulted in hightool life.
t = < 1,0 t = 1,0 – 1,2 t = 1,3 – 1,5 t = 1,6 – 2,0
normal tool life range
Individual sheet metal thickness [mm]
160.000
140.000
120.000
100.000
80.000
60.000
40.000
20.000
0Num
ber
of jo
ints
bef
ore
tool
cha
nge
Tool life with stainless steelSheet metal material: stainless steel 1,4301 (A/SI 304) oily / TOX®-Point 8,0 mm
Material
500 000
400 000
300 000
200 000
100 000
Steel
normal tool life range
(2) Number of TOX® jointsuntil tool change
AluminiumSteelgalvanizedprepainted
Customers have alreadyachieved much higher tool life.
Mean value Fs in NMean value Fk in NTensile strength Shear strength
Retainingforce in N
Type of Joint
Comparison of Joint Strength for Various Joining at AC120 1,25 mm into 1,25 mm
TOX® ClinchRivet Pierce rivet X Pierce rivet Y
Cos
t pe
r 10
0.00
0 jo
ints
in E
uro
Tooling Operating costs Investment
TOX® joining Spot welding
(1) Cost per joining
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The TOX® Joining Systems:Simplicity is our strength.
The patented TOX® round joint is the core of our technolo-gy. A simple round punch presses the materials to be joinedinto the die cavity. As the force continues to increase, thepunch side material is forced to spread outwards within thedie side material. The result: an aesthetically pleasing roundbutton, which joins clearly without any burrs or sharp edgeson which corrosion could set in. Even with aluminized orgalvanized sheet metals, the anti-corrosive propertiesremain intact as the protective layer flows with the material.Find additional information in the data sheet 80.100.
In some instances, the button formed by the TOX® point may be undesirable.That’s why we developed theTOX® flat joint.
TOX® Round Joint TOX® Flat Joint
The TOX® round joint:Smart Joining Technology withno added fasteners.Strength:The materials are plasticallydeformed in the joining area, there-fore, increasing the strength. Thereare no stress concentration factors.The advantages of the TOX® joiningsystem can also be appreciated inregards to the environment - par-ticularly in comparison to welding.Just think of welding aluminium,galvanized or prepainted sheetmetal!Cutting costs with TOX®
Besides the directly measurablecost advantages, considerablesavings can also be made with amuch simpler production sequence.For example, it is often possible topunch, bend and join in one pro-gressive die. This saves an entireworking cycle as well as transporta-tion to the joining station - or weld-ing shop. Which is a great advan-tage in terms of logistics.
Process sequenceForming the TOX® flat joint:• the first step is to produce the
standard TOX® round joint• The resulting button is flattened
in a secondary operation.
The high shear and pull strengthsof the TOX® round joint are left vir-tually intact.
Process sequence
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In the case of the patented TOX® ClinchRivet, the actualrivet joining is made from a simple cylinder rivet in a joiningprocess using drawing/pressing methods. Similar to theTOX® round joint, the material to be joined is not cut but ledthrough the die form thus producing a very resistant joint -also in the case of thin materials.
Multijoint applications increase cost advantages.Find additional information in the corresponding data sheet.
TOX® ClinchRivet
The special advantage of the TOX®
ClinchRivet is the simple, symme-trical and inexpensive rivet. Thisresults in the troublefree feed andcompression. The materials to bejoined gain an additional retainingcomponent. A clean and highlyreproducible joint is created.
All technological characteristicsand quality criteria of the TOX®
round joint also apply to the TOX®
ClinchRivet.
Process sequence
A special die has solid and flexible segments. The materi-als and the punch are centered by the fixed segments,thereby guaranteeing that the joint formation is perfectlyconcentric. The mobile elements between the solid seg-ments allow an interlocking of the material in the joint.
TOX®-SKB
The advantages are seen in amore flat protrusion of the jointand a higher flexibility when sheetmetals of different thickness haveto be joined with one tool set.
The special arrangement of thesprings allows extremely slendertools and thus better accessibilityand minimal interference com-pared with conventional die con-struction without solid part.
The SKB die shows its strengthspecially when glue is usedbetween the sheet metal layers.
Process sequence
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Specialities of the procedure
Process sequence Process sequence
The TOX® point for difficult casesapplications and advantages:- Joining of sheet metals with large differences in thickness (differences from 1/4 to 4/1 can be realized).- Joining of high strength materials with ductile materials.- Joining of a non-ductile or high tensile strength sheet metal material with a ductile one, e.g. joining of sheet
metal and cast steel/spring steel combinations.- Joining of sheet metals with non-metallic materials (e.g. plastics, elastomers, paper, cardboard).
TOX® Vario Joint I TOX® Vario Joint II
Features:- Requires one material to be pre-punched- Forming of only one sheet metal layer- Able to take both radial and axial force
- Low joining force requirement- Exact positioning of the components required- Multipoint capability
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TOX® Standards:The modular program - flexible and field-proven
TOX® Tools
TOX® flat plate dieoffers unbeatable accessin hard to reach corners.
TOX® Tool Holderwith integrated stripper
TOX® Robot- and Machine tongswith pneumo-hydraulic, electric-or hydraulic drive.
TOX® Production MachineTOX®-Presses with integratedmulitpoint die sets.Our know-how, your advantage.
TOX® Die Setsthe most economical way to useTOX®. Multiple points can beproduced in one operation.
TOX® PowerKurverfor simultaneousclamping and joining. No need for repeated clamping andfixturing. Optimal accessibility for largepanels due to > 90° operating angle.With pneumatic or electric drive.
TOX® Handtongsthe suspensionoffers an optimumhandling.
TOX® Tongs Fixturesin single and multipoint design,specially adapted to your component.They are pneumatic, pneumatic-hydraulic or hydraulic driven.
TOX® ClinchRivetstandardized swage heads includingfeed and fill level control for installa-tion in single and multijoint applicati-ons. Appropriate for robots.
TOX®-FinePressHigh-quality benchtop presses –compact and perfect.
10
KN
30
25
20
15
10
5
07 6 5 4 3 2 1 0
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The specially adapted process moni-toring system for the TOX® joiningtechnique helps you to check thecompetitive factor of quality:• for each produced component• for each clinch point in the
component
A cost effective production monito-ring for short cycle times requires acontrol system which is integrated intothe line - in short, a system like theTOX® process monitoring system.
The TOX® process monitoring systemguarantees your quality standards,not only for mass production, butalso for small-scale manufacturing.
TOX® process monitoring keeps a constant check on your clinch points.
Functional principle:Force sensors measure the press for-ce at the clinch points. A position indi-cator monitors the attainment of con-trol dimension “X” (quality dimension).Once the position indicator signalsthat control dimension “X” has
been reached, the press forces mea-sured by the load cells are comparedwith the nominal press forces. TheTOX® point is satisfactory if the mea-sured press force lies within the pre-set tolerance range. Thus, it is possi-ble to make an assessment on mate-
rial type, strength and thickness, righttool combination as well as tool failureor missing layer of sheet metal.As alternative it is possible to evalua-te the complete Force-Travel charac-teristic curve (EPWL measuring prin-ciple).
Resistance to pull and shear loads isdependent on the control dimension“X”, provided that the joining parame-ters and the service life of the toolshave been observed.
Evaluation Units for Monitoring of Clinch Processes
- Force monitoring of clinching processes
- Trend monitoring- Process sequencing- Network capability over Ethernet
TCP/IP- Expandable to userdefined
processes- With and without display
TOX® process monitoring CEP 400
TOX®-ToolCheck pneumatic testing of clinching dies
The die monitoring system TOX®-ToolCheck, together with the processmonitoring, checks the condition ofthe TOX® Clinching dies. This ensu-res that the joining process is alwaysperformed with an intact die. Anypotential defects, like missing or (e.g.
by contamination) jammed movingelements of the SKB die, as well asruptures on either the solid TOX® dieor on the fixed segments of SKB, areidentified within < 1 second.
For detailed information, see TOX®
Data Sheet 80.06.
The evaluation device can be selec-ted according to each requirement.From 1- to 16-channel clinch monito-ring all the way to continuous measu-ring in force-travel-pressing monito-ring.
Various evaluation methods allow fordifferent analysis of your processes.Diverse communication interfacesallow for simple and quick data trans-fer to the data storage.
X-Dimension (mm)
Punch
Compres-sed Air
Stripper
Die
TOX®softWare
EthernetInterbus/ServiceNet/Profibus
RS 232/485PLC
See “TOX®-Controls”
catalog for detailed
informationTOX®-ControlsandTOX®-Monitoring
NETWORK
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The X-dimension defines the joint quality!
Now it’s possible to precisely controlthe X dimension, the remaining bottomthickness of the joint after the clinchingprocess, by simultaneously compensatingfor the deflection of the press unit.
Controlled Precision Clinchingusing Electric Servo Drives
Typical Application:TOX®-Clinch Robot-Tongs with a compact electromechanical ser-vo drive EPMK and controller including the free TOX®softWare.
Process monitoring using envelope curves
+ Full monitoring within the set point and target windows, i.e. the force/travel characteristics curve can not fall outside theupper and lower limits
+ Decide for yourself!For curves deviating from the envelope, these options apply:
process will continue until target window is reachedstop process
+ TOX®softWareIncluded with delivery: This software, specially developed by TOX®, integrates all appropriately equipped TOX® pro-ducts. Programming, visualization and displaying, network-ing and archiving, all this can be done using a common platform.
set point
envelope
target window
TOX®softWare = User friendly
+ Automated learning of the processes and the forcelimits in the target window, as well as for the envelope.
+ No programming, only parameterizing
+ automatic scaling of the envelope display
+ simple, user friendly user platform
The X dimension is determined in the TOX test labs.A tolerance range of ± 15 % is acceptable.
Now: + active stabilization of variancestechnical optimum achieved with an accuracy of ± 0,04 mm
+ Flexibility, precision, minimum setup times
+ the X dimension is assured independent ofmaterial combination and properties
Point diameter
Controldimension "X"Controldimension "X"
ePunch sideDie side
The upper picture shows: the measuring structureThe lower picture shows: examples of available movefunctions
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Our Worldwide Sales and Service Network
TOX® PRESSOTECHNIKRiedstraße 4D-88250 WeingartenTel. +49 (0) 7 51 / 50 07-0Fax +49 (0) 7 51 / 5 23 91E-Mail: [email protected]
GMBH &CO. KG
80.0711.02 Subject to technical alternations.
TOX®-Production
Systems
TOX®-Fastener-
Insertion
TOX®-Piercing
and Marking
TOX®-Tongs
TOX®-Joining-
Systems
TOX®-Controls,
TOX®-Monitoring
TOX®-Presses
TOX®-FinePress
TOX®-ElectricDrive
TOX®-PowerKurver
TOX®-Powerpackage
Product Range