Fastening Technique for Hybrid Auto Body Structures
Ralf Birkelbach, EJOT GmbH & Co. KG
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Content
Design and material changes in automotive industry
Joining requirement specification
Basic fastener development:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
Folie 2
Content
Design and material changes in automotive industry
Joining requirement specification
Basic fastener development:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Design and material changes in automotive industry
Steel
Aluminum
Glass
Plastics
Others
Quelle: Cluster „Neue Werkstoffe in Bayern“ 2006
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Design and material changes in automotive industry
Various stages of light weight design in the body in white structure
Al- Die cast
Al- Extruded profile
Al- Sheet
St – High strength (22MnB5)
Structure Steel
Hang- ons Steel
Structur Steel
Hang- ons Al
Structure Steel
plate parts Al
Hang- ons Al
Structure Al/Steel
plate parts Al
Source: AUDI AG EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
Hang- ons Al
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Content
Design and material changes in automotive industry
Joining requirement specification
Basic developments:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Joining Requirement Specification
Joining different materials together (with minimized preparation)
Solutions for fixing, attachement and structural (high strength) joints
Assembly with and without adhesive between the layers
One side access for fixing into aluminum extrusions (e. g. Space-framedesign)
Accurate assembly without distortion
High dynamic resistance
Crash safety
Fully automated assembly process
High reliability / process control
Multi layer applications
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
Folie 7
Content
Design and material changes in automotive industry
Joining requirement specification
Basic fastener development:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
Folie 8
FDS® screw design
Head with recess inside /
outside
Usable thread length
Thread forming part
Flowdrilling section
Point (tip) of the screw
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Stages of the FDS® assembly
1.
4.
2.
5.
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
3.
6.
1.
Warming up the sheet
metal by axial end load
and high speed
2.
Penetration into the material
3.
Forming of the extrusion
4.
Chipless forming of a
female machine thread
5.
Installation
6.
Tightening with the
pre-set torque
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torque (Nm)
Torque plot of an FDS® joint
Ts
TT
Forming of the extrusion
2.
Thread forming
3.
Engagement of full threads
4.
Tightening
Ti = installation Torque
4.
TT = tightening Torque
Ti
2.
1.
1.
TS = stripping Torque
3.
time (sec.)
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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System for fullautomated FDS Robot-assembly (left)
and feeding system (right)
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Fully automated FDS® assembly (with clearance hole)
1.
2.
3.
4.
5.
6.
n: speed
M: torque
F: endload
Finding
Warm
up
EJOT GmbH
& Co. KG • April 2012
• Ralf Birkelbach
Draft forming Thread forming
Drive in
Tightening
Folie
13
FDS® Example in Aluminum (with clearance hole)
EN AW-5754
t=1,15 mm
EN AW-6082-T6
t=3.2 mm
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Content
Design and material changes in automotive industry
Joining requirement specification
Basic developments:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Series Applications with Selfpiercing and Extruding Screws
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Application examples (with clearance hole)
Lamborghini Gallardo: fully automated assembly at Thyssen Krupp Drautz
• Fixation of the base plate (1 mm)
onto Aluminum body frame (3 mm)
• 160 FDS® M5 x 18 without pilot hole
source: Audi AG
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Application examples (with clearance hole)
Ferrari California: assembly of the tunnel
Assembly of 100 FDS® M5x18
screws without pilot hole into:
• Aluminium profile with
thicknesses:
- 1,25mm EN AW-6181-A T4
- 1,5mm EN AW-6181-A T4
- 2,0mm EN AW-6063 T6
- 3,9mm EN AW-6063 T6
Clamped part:
• Aluminium die-cast material
- 2mm C611 T5
with 7mm clearance hole
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Application examples (with clearance hole)
Audi TT Coupe/Roadster:
fully automated robot assembly in the „body in white“ production
Robot-assembly (12 systems) for 229
FDS® M5 screws (255 for Roadster)
without pilot hole into:
• Aluminium profile: thickness 1,5 up to
3,5mm
• Aluminium die-cast material up to 3mm
• Clearance hole diam.: 7mm
• 80% of the FDS assembly into
aluminium profile
• 75% in combination with adhesive
(no adhesive in the clearance hole)
source: Audi AG
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Application examples (with clearance hole)
Audi TT Coupe/Roadster:
fully automated robot assembly in the „body in white“ production
Material– mix assembly
Steel plate 1,2 mm on aluminium profile 2,5 mm
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Application examples (with clearance hole)
Audi TT Coupe/Roadster:
fully automated robot assembly in the „body in white“ production
Fixation of aluminium sheet 1,15mm on
- 1,5 mm aluminium frame rail
- 3 mm aluminium die-cast
- 2 mm aluminium cross beam
with different tightening torques
A-pillar
Fixation of car body shell 1,15 mm on
aluminium die-cast 3 mm
Demo Video
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Content
Design and material changes in automotive industry
Joining requirement specification
Basic developments:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Further optimized FDS® screw design
Head with recess outside /
inside
Increased underhead bulge
Usable thread length
Thread forming part
Flowdrilling section
Point (tip) of the screw
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Process steps of FDS® assembly without part preparation
= Downholder
2.
1.
Heating
3.
Penetrating
Extrusion
forming
5.
4.
Thread
forming
Engagement of
full threads
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
6.
Tightening
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Assembly principles
Material combination and downholder design for assembly without
clearance hole
Fastening
direction
Clamped part (without
clearence hole)
Note:
Preferred material combination:
Installation part
• „Thin“ on „Thick“ and/or.
• „weak“ on „hard“
Adjustable downholder force
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Fully automated FDS® assembly (without holes)
1.
2.
3.
4.
5.
6.
n: speed
M: torque
F: endload
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
Finding
Warm up
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Draft forming Thread forming
Drive in
Tightening
FDS® Example in Aluminum (without holes)
EN AW-5754
t=1.5mm
EN AW-6082-T6
t=3.8mm
Demo Video
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Content
Design and material changes in automotive industry
Joining requirement specification
Basic developments:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Application examples (without holes)
Audi R8:
Fully automated robot assembly in the „body in white“ production
Assembly of 310 FDS® M5 screws
without pilot and clearance hole
into:
• Aluminium profile:
thickness 1,5 up to 3,5mm
• Aluminium die-cast:
up to 3mm
• Max. clamped part thickness
1,15mm
source: Audi AG
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Application examples (without holes)
Audi R8:
Fully automated robot assembly in the „body in white“ production
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Application examples (without holes)
Audi A8 (D4): FDS® Screw M5x20
Fully automated robot assembly in the „body in white“ production
Assembly:
• Installation parts:
- 1,0 bis 4,8mm Aluminium profile
- 2,5 bis 3,5mm Aluminium die-cast
• Clamped parts:
- Aluminium (with and mostly without
clearance hole)
•
740 FDS® M5 x 20 (per car)
• 18 joints as 3-layers
source: Audi AG
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Guideline and recommendations
Preferred conditions:
• clamped part thickness <= installation part thickness
• clamped part thickness max. 30% higher than underhead bulge
• clamped part hardness <= installation part hardness
• max. tensile strength installation part: ~ 800 MPa
Advantages:
• no hole operation at all
• no consideration of tolerances
• structure fixing with or without adhesive
• one side access assembly
Disadvantage:
• special headstyle required
• screw more expensive than with ordinary headsytle
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Content
Design and material changes in automotive industry
Joining requirement specification
Basic developments:
Fastener design and assembly principles
Automotive applications with clearance hole
Further developments:
Optimized screw design and assembly principles
Automotive applications without any hole
Multi layer applications
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Multi layer FDS® screw design
Head with recess outside /
inside
Increased underhead buldge
Usable thread length
Thread forming part
Calibration part
Flowdrilling section
Point (tip) of the screw
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Multi-layer application (3-layer Material Mix Aluminum/Steel)
FDS M5x25
• Installation part: HC 340 LA (2mm)
• Clamped part 1: Aluminium EN AW-6181 (1,5mm)
• Clamped part 2: Aluminium EN AW-6181 (1,5mm)
Ti
(Nm)
Ts
(Nm)
t
Process
(sec.) end
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Multi- layer application (3- layer stack-up of Aluminum)
FDS M5x25
• Installation part: Aluminium EN AW-6181 (2,0mm)
• Clamped part 1: Aluminium EN AW-6181 (1,5mm)
• Clamped part 2: Aluminium EN AW-6181 (1,5mm)
Ti
(Nm)
Ts
(Nm)
t
Process
(sec.) end
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Multi- layer application (4- layer stack-up of Aluminum)
FDS M5x25
• Installation part: Aluminium EN AW-6181 (1,5mm)
• Clamped part 1: Aluminium EN AW-6181 (1,5mm)
• Clamped part 2: Aluminium EN AW-6181 (1,5mm)
• Clamped part 3: Aluminium EN AW-6181 (1,5mm)
Ti
(Nm)
Ts
(Nm)
t
Process
(sec.) end
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Multi layer FDS® screw design
Head with recess outside /
inside
Increased underhead buldge
thread
length joints
Can and is also being usedUsable
for the
2 layer
Thread forming part
Calibration part
Flowdrilling section
Point (tip) of the screw
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Fulfillment of Joining Requirement Specification
Joining different materials together
Solutions for fixing, attachement and structural joints
Assembly with and without adhesive between the layers
One side access for fixing into aluminum extrusions (e. g. Space-framedesign)
Accurate assembly without distortion
High dynamic resistance
Crash safety
Fully automated assembly process
High reliability / process control
Multi layer applications
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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Thank you for your Attention !
www.ejot.de
EJOT GmbH & Co. KG • April 2012 • Ralf Birkelbach
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