US20180126445A1 - Hybrid workpiece joining - Google Patents
Hybrid workpiece joining Download PDFInfo
- Publication number
- US20180126445A1 US20180126445A1 US15/348,595 US201615348595A US2018126445A1 US 20180126445 A1 US20180126445 A1 US 20180126445A1 US 201615348595 A US201615348595 A US 201615348595A US 2018126445 A1 US2018126445 A1 US 2018126445A1
- Authority
- US
- United States
- Prior art keywords
- fastener
- workpiece
- nose
- zone
- joining device
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J15/00—Riveting
- B21J15/10—Riveting machines
- B21J15/36—Rivet sets, i.e. tools for forming heads; Mandrels for expanding parts of hollow rivets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J15/00—Riveting
- B21J15/10—Riveting machines
- B21J15/14—Riveting machines specially adapted for riveting specific articles, e.g. brake lining machines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J15/00—Riveting
- B21J15/02—Riveting procedures
- B21J15/025—Setting self-piercing rivets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J15/00—Riveting
- B21J15/02—Riveting procedures
- B21J15/08—Riveting by applying heat, e.g. to the end parts of the rivets to enable heads to be formed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J15/00—Riveting
- B21J15/10—Riveting machines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J15/00—Riveting
- B21J15/10—Riveting machines
- B21J15/12—Riveting machines with tools or tool parts having a movement additional to the feed movement, e.g. spin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J15/00—Riveting
- B21J15/10—Riveting machines
- B21J15/14—Riveting machines specially adapted for riveting specific articles, e.g. brake lining machines
- B21J15/147—Composite articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J15/00—Riveting
- B21J15/10—Riveting machines
- B21J15/16—Drives for riveting machines; Transmission means therefor
- B21J15/26—Drives for riveting machines; Transmission means therefor operated by rotary drive, e.g. by electric motor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/002—Joining methods not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
- B29C65/562—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7841—Holding or clamping means for handling purposes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
- B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
- B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
- B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
- B29C66/81421—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
- B29C66/81423—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being concave
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
- B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
- B29C66/8187—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the electrical insulating constructional aspects
- B29C66/81871—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the electrical insulating constructional aspects of the welding jaws
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
- B29C66/832—Reciprocating joining or pressing tools
- B29C66/8322—Joining or pressing tools reciprocating along one axis
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
- B29C65/3404—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint
- B29C65/3408—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint comprising single particles, e.g. fillers or discontinuous fibre-reinforcements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
- B29C66/024—Thermal pre-treatments
- B29C66/0242—Heating, or preheating, e.g. drying
Definitions
- the present disclosure relates to a workpiece assembly including a fastener and a joining method thereof.
- Joining of both ferrous and non-ferrous materials can be achieved through various methods.
- a self-piercing rivet can be driven under pressure into the members.
- a die or mandrel may disrupt a terminal end of the self-piercing rivet in order to create a mechanical interference between the members and the rivet.
- an ultrasonic welding device can use high-frequency ultrasonic vibrations to generate heat at an interface of the workpieces. The heated workpieces may melt sufficiently to create a joint at the interface.
- a joining device includes a nose, a punch, and a die anvil.
- the punch is coaxially slidable within the nose.
- a fastener is arranged within the nose and is coaxially slidable within the nose and movable by the punch.
- An ultrasonic vibration is focused through the die anvil to a zone on a material assembly arranged thereon for heating the zone.
- the punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.
- the material assembly includes a first and second workpiece and the fastener is configured to join the first workpiece to the second workpiece.
- the fastener further includes a head and a shank extending from the head, and the punch may contact the fastener at the head and drive the shank through the first workpiece and into the second workpiece.
- the die anvil has a die face that receives the second workpiece when the shank of the fastener is in the zone, and the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces. Additionally, at least a portion of the zone on the material assembly is fused upon cooling of the zone.
- a joining device includes a nose horn, a punch coaxially slidable within the nose horn, and a die having a material assembly arranged thereon.
- a fastener is arranged within the nose horn and is coaxially slidable within the nose horn and movable by the punch.
- the nose horn is axially movable to a position contacting the material assembly.
- An ultrasonic vibration is focused through the nose horn to a zone on the material assembly for heating the zone.
- the punch is configured to drive the fastener outwardly from the nose horn and into the material assembly at the zone.
- the material assembly includes a first and second workpiece and the fastener is configured to join the first workpiece to the second workpiece.
- the fastener further includes a head and a shank extending from the head, and the punch may contact the fastener at the head and drive the shank through the first workpiece and into the second workpiece.
- the die has a die face that receives the second workpiece when the shank of the fastener is in the zone, and the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces. Additionally, at least a portion of the zone on the material assembly is fused upon cooling of the zone.
- a joining device includes a nose, a punch, and an electrode die.
- the punch is coaxially slidable within the nose.
- a fastener is arranged within the nose and is coaxially slidable within the nose and movable by the punch.
- An electrical current is focused through the electrode die to a zone on a material assembly arranged thereon for heating the zone.
- the punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.
- the electrode die includes an insulator (e.g., ceramic or polymer), a first conductor (e.g., tungsten carbide) arranged about the insulator, and a second conductor (e.g., steel) arranged on an end surface of the first conductor, with the second conductor configured to contact the material assembly.
- the material assembly can include a first and second workpiece with the fastener configured to join the first workpiece to the second workpiece.
- the fastener further includes a head and a shank extending from the head, and the punch may contact the fastener at the head and drive the shank through the first workpiece and into the second workpiece. Additionally, at least a portion of the zone on the material assembly is fused upon cooling of the zone.
- an electrical power source can be interconnected with the electrode die to selectively create an electrical circuit for conducting electrical current through the first and second conductors, where the electrical current at the second conductor locally heats the second workpiece.
- FIGS. 1A through 1E depict schematic views of an exemplary hybrid joining machine according to the present disclosure
- FIG. 2 is a flow diagram of an exemplary hybrid joining process utilizing the hybrid joining machine of FIGS. 1A through 1E ;
- FIGS. 3A through 3E depict schematic views of another exemplary hybrid joining machine according to the present disclosure
- FIG. 4 is a flow diagram of another exemplary hybrid joining process utilizing the hybrid joining machine of FIGS. 3A through 3E ;
- FIGS. 5A through 5E depict schematic views of yet another exemplary hybrid joining machine according to the present disclosure.
- FIG. 6 is a flow diagram of yet another exemplary hybrid joining process utilizing the hybrid joining machine of FIGS. 5A through 5E .
- each of the exemplary hybrid joining machines includes a nose 12 , a punch 14 , and a die 16 .
- the hybrid joining machines can be used to join first and second workpieces 18 , 20 with a fastener 22 .
- the fastener 22 can be a rivet having a head portion 24 and a generally cylindrical hollow shank 26 ending in a tapered extremity 28 .
- the rivet 22 is configured to mechanically fasten the first and second workpieces 18 , 20 when subjected to a driving force, such as may be achieved by the punch 14 acting on the rivet 22 .
- the rivet 22 is referred to as a “self-piercing” rivet, as the tapered extremity 28 is sufficient to cause penetration of the workpieces 18 , 20 under the force of the punch 14 .
- the shank 26 is configured to deform to create a mechanical joint without requiring a lead hole for the rivet 22 in the workpieces 18 , 20 .
- an exemplary hybrid joining machine 10 incorporates a hybrid joining technique involving the mechanical fastening of riveting with an ultrasonic energy applied to the second workpiece 20 .
- line power e.g., low-frequency electrical signal of about 50-60 Hz
- high frequency electrical signal e.g., 15-70 kHz, and more particularly 20-40 kHz
- the high frequency electrical signal is then converted to a mechanical vibration at an ultrasonic frequency in a converter (i.e., transducer).
- An optional booster may be included in the system in order to amplify the mechanical vibration such that the vibration amplitude can be increased.
- the ultrasonic vibrations then propagate through the die anvil 16 .
- An end face 30 of the die anvil 16 can then focus the ultrasonic vibration and deliver the vibration energy to a specified area on a material (e.g., at a portion of the second workpiece 20 to be riveted).
- first and second workpieces 18 , 20 are arranged on the die anvil 16 such that the second, lower workpiece 20 rests directly on the die anvil 16 and the first, upper workpiece 18 rests on the lower workpiece 20 , as shown in FIG. 1A .
- the nose 12 is actuated by hydraulic pressure so as to behave as a retractable clamping cylinder for the machine 10 .
- the nose 12 is driven downwardly towards the upper workpiece 18 to urge the workpieces 18 , 20 against the die anvil 16 , as shown in FIG. 1B .
- other drive mechanisms may be used for driving the nose 12 , e.g., an electrically powered screw assembly, an electrically powered actuator, or via a spring.
- the die anvil 16 is excited with ultrasonic vibration so as to locally heat the workpieces 18 , 20 .
- the transmitted waves are bounced back by the die anvil 16 .
- the mechanical waves from the vibration cause the workpieces 18 , 20 to oscillate (i.e., deform).
- the oscillations of the workpieces 18 , 20 generate heat at the both the interface between the die anvil 16 and workpiece 20 and at the interface between the workpieces 18 , 20 creating a localized heated material zone 32 .
- the punch 14 which is coaxially slidable within the nose 12 , is actuated so as to drive the rivet 22 into the upper workpiece 18 (see FIG. 1C ).
- the punch 14 continues driving the rivet 22 until the rivet 22 penetrates the lower workpiece 20 .
- the punch 14 contacts the head portion 24 and pierces the upper workpiece 18 with the shank 26 only partially piercing and entering, but not completely passing through the lower workpiece 20 (i.e., does not pass through the bottom surface of the lower workpiece 20 ).
- the localized heated material zone 32 allows for enhanced riveting since stresses and friction in this material zone are reduced.
- step 60 the shank 26 and the material of the lower workpiece 20 immediately adjacent to the shank 26 are then deformed through interaction with the die anvil 16 .
- the bottom surface of the lower workpiece 20 is subjected to the force of the die anvil 16 as described herein such that the shape of the surface of the lower workpiece 20 is modified to conform to the shape of the die anvil 16 .
- the complementary shape on the lower workpiece 20 mechanically interlocks the workpieces 18 , 20 .
- a fused region 34 is created at an interface between the workpieces 18 , 20 .
- the mechanical joint is supplemented by the fused region 34 between the upper and lower workpieces 18 , 20 .
- the fused region 34 contributes to the strength of the mechanical interface.
- the fused region 34 is most conveniently achieved if both the workpieces 18 , 20 are thermoplastic composite materials, having similar melting temperatures.
- the workpieces 18 , 20 may be alternate materials, including materials different from one another provided they are weldably compatible.
- the fused region 34 should be considered representative of a wide range of fused areas that may result from this process.
- the extent of fused region 34 may vary. However, to strengthen the interface and ease the insertion of the rivet 22 , at least a minimum localized heated material zone 32 should be developed around the circumference of shank 26 .
- the punch 14 and nose 12 are withdrawn from the riveted workpieces 18 , 20 and the riveted workpieces 18 , 20 are removed from the die anvil 16 (see FIG. 1E ).
- the assembled workpieces 18 , 20 and rivet 22 provide a robust weld, capable of withstanding delamination and microcracking.
- an exemplary hybrid joining machine 100 incorporates a hybrid joining technique involving the mechanical fastening of riveting with an ultrasonic energy applied to a workpiece.
- line power e.g., low-frequency electrical signal of about 50-60 Hz
- high frequency electrical signal e.g., 15-70 kHz, and more particularly 20-40 kHz
- the high frequency electrical signal is then converted to a mechanical vibration at an ultrasonic frequency in a converter (i.e., transducer).
- An optional booster may be included in the system in order to amplify the mechanical vibration such that the vibration amplitude can be increased.
- the ultrasonic vibrations then propagate through a nose horn 112 .
- An end face 136 of the nose horn 112 can then focus the ultrasonic vibration and deliver the vibration energy to a specified area on a material (e.g., at a portion of a first workpiece 118 to be riveted).
- first and second workpieces 118 , 120 are arranged on a die 116 such that the second, lower workpiece 120 rests directly on the die 116 and the first, upper workpiece 118 rests on the lower workpiece 120 , as shown in FIG. 3A .
- the nose horn 112 is actuated by hydraulic pressure so as to behave as a retractable clamping cylinder for the machine 100 .
- the nose horn 112 is driven downwardly towards the upper workpiece 118 to urge the workpieces 118 , 120 against the die 116 , as shown in FIG. 3B .
- other drive mechanisms may be used for driving the nose horn 112 , e.g., an electrically powered screw assembly, an electrically powered actuator, or via a spring.
- the nose horn 112 is excited with ultrasonic vibration so as to locally heat the workpieces 118 , 120 .
- the mechanical waves from the vibration cause the workpieces 118 , 120 to oscillate (i.e., deform).
- the oscillations of the workpieces 118 , 120 generate heat at both the interface between the nose horn 112 and the workpiece 118 and at the interface between the workpieces 118 , 120 creating a localized heated material zone 132 .
- a punch 114 which is coaxially slidable within the nose horn 112 , is actuated so as to drive a rivet 122 into the upper workpiece 118 .
- the punch 114 continues driving the rivet 122 until the rivet 122 penetrates the lower workpiece 120 (see FIG. 3C ).
- the punch 114 contacts a head portion 124 of the rivet 122 and pierces the upper workpiece 118 with a shank 126 of the rivet 122 only partially piercing and entering, but not completely passing through the lower workpiece 120 (i.e., does not pass through the bottom surface of the lower workpiece 120 ).
- the localized heated material zone 132 allows for enhanced riveting since stresses and friction in this material zone are reduced.
- the shank 126 and the material of the lower workpiece 120 immediately adjacent to the shank 126 are deformed through interaction with the die 116 .
- the bottom surface of the lower workpiece 120 is subjected to the force of the die 116 as described herein such that the shape of the surface of the lower workpiece 120 is modified to conform to the shape of the die 116 .
- the complementary shape on the lower workpiece 120 mechanically interlocks the workpieces 118 , 120 , as shown in FIG. 3D .
- a fused region 134 is created at an interface between the workpieces 118 , 120 .
- the mechanical joint is supplemented by the fused region 134 between the upper and lower workpieces 118 , 120 .
- the fused region 134 contributes to the strength of the mechanical interface.
- the fused region 134 is most conveniently achieved if both the workpieces 118 , 120 are thermoplastic composite materials, having similar melting temperatures.
- the workpieces 118 , 120 may be alternate materials, including materials different from one another provided they are weldably compatible.
- the fused region 134 should be considered representative of a wide range of fused areas that may result from this process.
- the extent of the fused region 134 may vary. However, to strengthen the interface and ease the insertion of the rivet 122 , at least a minimum localized heated material zone 132 should be developed around the circumference of shank 126 .
- the punch 114 and nose 112 are withdrawn from the riveted workpieces 118 , 120 and the riveted workpieces 118 , 120 are removed from the die 116 (see FIG. 3E ).
- the assembled workpieces 118 , 120 and rivet 122 provide a robust weld, capable of withstanding delamination and microcracking.
- an exemplary hybrid joining machine 200 incorporates a hybrid joining technique involving the mechanical fastening of riveting with an electrode energy (i.e., Joule heat) applied to a workpiece.
- an electrical power source may be connected to a die to create an electrical circuit that generates heat at a specified area on a material (e.g., at a portion of a workpiece to be riveted).
- a lower electrode die 216 may be split into a first portion 238 , also referred to as an insulator (e.g., polymer, ceramic); a second portion 240 , also referred to as a first conductor (e.g., tungsten carbide); and a washer 242 , also referred to as a second conductor (e.g., steel).
- the insulator 238 may be formed with the first conductor 240 to establish an interior wall 244 of the die 216 .
- the second conductor 242 may be arranged on an end surface 230 of the first conductor 240 so as to contact a lower workpiece 220 .
- An electrical power source 246 may be interconnected with the die 216 at the first conductor 240 , in order to selectively create an electrical circuit.
- the electrical circuit runs through the electrically conducting components of the assembly, namely from the first conductor 240 through the second conductor 242 and out again through the first conductor 240 .
- the electrical energy running through the second conductor 242 locally heats the lower workpiece 220 .
- first and second workpieces 218 , 220 are arranged on the die 216 such that the second, lower workpiece 220 rests directly on the die 216 and the first, upper workpiece 218 rests on the lower workpiece 220 , as shown in FIG. 5A .
- the nose 212 is actuated by hydraulic pressure so as to behave as a retractable clamping cylinder for the machine 200 .
- the nose 212 is driven downwardly towards the upper workpiece 218 to urge the workpieces 218 , 220 against the die 216 , as shown in FIG. 5B .
- other drive mechanisms may be used for driving the nose 212 , e.g., an electrically powered screw assembly, an electrically powered actuator, or via a spring.
- the electrical power source 246 is initiated and electrical current flows through the first conductor 240 to the second conductor 242 , around the second conductor 242 , and back out through the opposite side of the first conductor 240 , as depicted by arrows 248 .
- the electrical current passing through the second conductor 242 locally generates joule heat, consequently heating the workpieces 218 , 220 .
- the heat may propagate through the workpiece 220 creating a localized heated material zone 232 .
- a punch 214 which is coaxially slidable within the nose 212 , is actuated so as to drive a rivet 222 into the upper workpiece 218 .
- the punch 214 continues driving the rivet 222 until the rivet 222 penetrates the lower workpiece 220 (see FIG. 5C ).
- the punch 214 contacts a head portion 224 of the rivet 222 and pierces the upper workpiece 218 with a shank 226 of the rivet 222 only partially piercing and entering, but not completely passing through the lower workpiece 220 (i.e., does not pass through the bottom surface of the lower workpiece 220 ).
- the localized heated material zone 232 allows for enhanced riveting since stresses and friction at least in this material zone are reduced.
- the shank 226 and the material of the lower workpiece 220 immediately adjacent to the shank 226 are deformed through interaction with the die 216 .
- the bottom surface of the lower workpiece 220 is subjected to the force of the die 216 as described herein such that the shape of the surface of the lower workpiece 220 is modified to conform to the shape of the die 216 .
- the complementary shape on the lower workpiece 220 mechanically interlocks the workpieces 218 , 220 , as shown in FIG. 5D .
- the electrical current from the electrical power source 246 may then be removed in order to allow the material zone 232 to cool.
- at least a minimum localized heated material zone 232 should be developed around the circumference of shank 226 .
- the punch 214 and nose 212 are withdrawn from the riveted workpieces 218 , 220 and the riveted workpieces 218 , 220 are removed from the die 216 (see FIG. 5E ).
- the assembled workpieces 218 , 220 and rivet 222 provide a robust weld, capable of withstanding delamination and microcracking.
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Abstract
A joining device includes a nose, a punch, and a die anvil. The punch is coaxially slidable within the nose. A fastener is arranged within the nose and is coaxially slidable within the nose and movable by the punch. An ultrasonic vibration is focused through the die anvil to a zone on a material assembly arranged thereon for heating the zone. The punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.
Description
- The present disclosure relates to a workpiece assembly including a fastener and a joining method thereof.
- The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
- Joining of both ferrous and non-ferrous materials can be achieved through various methods. In one example for joining overlapping members, a self-piercing rivet can be driven under pressure into the members. A die or mandrel may disrupt a terminal end of the self-piercing rivet in order to create a mechanical interference between the members and the rivet. In another example for joining overlapping members, an ultrasonic welding device can use high-frequency ultrasonic vibrations to generate heat at an interface of the workpieces. The heated workpieces may melt sufficiently to create a joint at the interface.
- A joining device includes a nose, a punch, and a die anvil. The punch is coaxially slidable within the nose. A fastener is arranged within the nose and is coaxially slidable within the nose and movable by the punch. An ultrasonic vibration is focused through the die anvil to a zone on a material assembly arranged thereon for heating the zone. The punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.
- In some embodiments, the material assembly includes a first and second workpiece and the fastener is configured to join the first workpiece to the second workpiece. The fastener further includes a head and a shank extending from the head, and the punch may contact the fastener at the head and drive the shank through the first workpiece and into the second workpiece. Furthermore, the die anvil has a die face that receives the second workpiece when the shank of the fastener is in the zone, and the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces. Additionally, at least a portion of the zone on the material assembly is fused upon cooling of the zone.
- A joining device includes a nose horn, a punch coaxially slidable within the nose horn, and a die having a material assembly arranged thereon. A fastener is arranged within the nose horn and is coaxially slidable within the nose horn and movable by the punch. The nose horn is axially movable to a position contacting the material assembly. An ultrasonic vibration is focused through the nose horn to a zone on the material assembly for heating the zone. The punch is configured to drive the fastener outwardly from the nose horn and into the material assembly at the zone.
- In some embodiments, the material assembly includes a first and second workpiece and the fastener is configured to join the first workpiece to the second workpiece. The fastener further includes a head and a shank extending from the head, and the punch may contact the fastener at the head and drive the shank through the first workpiece and into the second workpiece. Furthermore, the die has a die face that receives the second workpiece when the shank of the fastener is in the zone, and the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces. Additionally, at least a portion of the zone on the material assembly is fused upon cooling of the zone.
- A joining device includes a nose, a punch, and an electrode die. The punch is coaxially slidable within the nose. A fastener is arranged within the nose and is coaxially slidable within the nose and movable by the punch. An electrical current is focused through the electrode die to a zone on a material assembly arranged thereon for heating the zone. The punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.
- In some embodiments, the electrode die includes an insulator (e.g., ceramic or polymer), a first conductor (e.g., tungsten carbide) arranged about the insulator, and a second conductor (e.g., steel) arranged on an end surface of the first conductor, with the second conductor configured to contact the material assembly. The material assembly can include a first and second workpiece with the fastener configured to join the first workpiece to the second workpiece. The fastener further includes a head and a shank extending from the head, and the punch may contact the fastener at the head and drive the shank through the first workpiece and into the second workpiece. Additionally, at least a portion of the zone on the material assembly is fused upon cooling of the zone. Furthermore, the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces. In addition, an electrical power source can be interconnected with the electrode die to selectively create an electrical circuit for conducting electrical current through the first and second conductors, where the electrical current at the second conductor locally heats the second workpiece.
- Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
- The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
-
FIGS. 1A through 1E depict schematic views of an exemplary hybrid joining machine according to the present disclosure; -
FIG. 2 is a flow diagram of an exemplary hybrid joining process utilizing the hybrid joining machine ofFIGS. 1A through 1E ; -
FIGS. 3A through 3E depict schematic views of another exemplary hybrid joining machine according to the present disclosure; -
FIG. 4 is a flow diagram of another exemplary hybrid joining process utilizing the hybrid joining machine ofFIGS. 3A through 3E ; -
FIGS. 5A through 5E depict schematic views of yet another exemplary hybrid joining machine according to the present disclosure; and -
FIG. 6 is a flow diagram of yet another exemplary hybrid joining process utilizing the hybrid joining machine ofFIGS. 5A through 5E . - The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. Further, directions such as “top,” “side,” “back”, “lower,” and “upper” are used for purposes of explanation and are not intended to require specific orientations unless otherwise stated. These directions are merely provided as a frame of reference with respect to the examples provided, but could be altered in alternate applications.
- The present disclosure describes a hybrid technique for joining workpieces, such as polymeric composites, by a combination of integral fastening (e.g., self-piercing riveting) and localized material fusing. With reference to the drawings, wherein like reference numbers refer to like components, each of the exemplary hybrid joining machines includes a
nose 12, apunch 14, and adie 16. The hybrid joining machines can be used to join first andsecond workpieces fastener 22. In one exemplary embodiment, thefastener 22 can be a rivet having ahead portion 24 and a generally cylindricalhollow shank 26 ending in atapered extremity 28. Therivet 22 is configured to mechanically fasten the first andsecond workpieces punch 14 acting on therivet 22. Therivet 22 is referred to as a “self-piercing” rivet, as the taperedextremity 28 is sufficient to cause penetration of theworkpieces punch 14. Furthermore, theshank 26 is configured to deform to create a mechanical joint without requiring a lead hole for therivet 22 in theworkpieces - With reference now to
FIGS. 1A through 1E , an exemplaryhybrid joining machine 10 incorporates a hybrid joining technique involving the mechanical fastening of riveting with an ultrasonic energy applied to thesecond workpiece 20. In this regard, line power (e.g., low-frequency electrical signal of about 50-60 Hz) is converted to a high frequency, high voltage electrical signal (e.g., 15-70 kHz, and more particularly 20-40 kHz). The high frequency electrical signal is then converted to a mechanical vibration at an ultrasonic frequency in a converter (i.e., transducer). An optional booster may be included in the system in order to amplify the mechanical vibration such that the vibration amplitude can be increased. The ultrasonic vibrations then propagate through thedie anvil 16. An end face 30 of thedie anvil 16 can then focus the ultrasonic vibration and deliver the vibration energy to a specified area on a material (e.g., at a portion of thesecond workpiece 20 to be riveted). - With reference to
FIG. 2 , amethod 50 of joining theworkpieces hybrid joining machine 10 ofFIGS. 1A through 1E . Specifically, atstep 52, first andsecond workpieces die anvil 16 such that the second,lower workpiece 20 rests directly on thedie anvil 16 and the first,upper workpiece 18 rests on thelower workpiece 20, as shown inFIG. 1A . Atstep 54, thenose 12 is actuated by hydraulic pressure so as to behave as a retractable clamping cylinder for themachine 10. Thenose 12 is driven downwardly towards theupper workpiece 18 to urge theworkpieces die anvil 16, as shown inFIG. 1B . It should be noted that other drive mechanisms may be used for driving thenose 12, e.g., an electrically powered screw assembly, an electrically powered actuator, or via a spring. - At
step 56, thedie anvil 16 is excited with ultrasonic vibration so as to locally heat theworkpieces die anvil 16. The mechanical waves from the vibration cause theworkpieces workpieces die anvil 16 andworkpiece 20 and at the interface between theworkpieces heated material zone 32. Atstep 58, thepunch 14, which is coaxially slidable within thenose 12, is actuated so as to drive therivet 22 into the upper workpiece 18 (seeFIG. 1C ). Thepunch 14 continues driving therivet 22 until therivet 22 penetrates thelower workpiece 20. In particular, thepunch 14 contacts thehead portion 24 and pierces theupper workpiece 18 with theshank 26 only partially piercing and entering, but not completely passing through the lower workpiece 20 (i.e., does not pass through the bottom surface of the lower workpiece 20). Notably, the localizedheated material zone 32 allows for enhanced riveting since stresses and friction in this material zone are reduced. - At step 60 (see
FIG. 1D ), theshank 26 and the material of thelower workpiece 20 immediately adjacent to theshank 26 are then deformed through interaction with thedie anvil 16. The bottom surface of thelower workpiece 20 is subjected to the force of thedie anvil 16 as described herein such that the shape of the surface of thelower workpiece 20 is modified to conform to the shape of thedie anvil 16. The complementary shape on thelower workpiece 20 mechanically interlocks theworkpieces - Furthermore, as the localized
heated material zone 32 cools, a fusedregion 34 is created at an interface between theworkpieces region 34 between the upper andlower workpieces region 34 contributes to the strength of the mechanical interface. The fusedregion 34 is most conveniently achieved if both theworkpieces workpieces region 34 should be considered representative of a wide range of fused areas that may result from this process. Depending on the duration and magnitude of application of the ultrasonic vibration, the extent of fusedregion 34 may vary. However, to strengthen the interface and ease the insertion of therivet 22, at least a minimum localizedheated material zone 32 should be developed around the circumference ofshank 26. - At
step 62, thepunch 14 andnose 12 are withdrawn from the rivetedworkpieces workpieces FIG. 1E ). The assembledworkpieces - With reference now to
FIGS. 3A through 3E , an exemplaryhybrid joining machine 100 incorporates a hybrid joining technique involving the mechanical fastening of riveting with an ultrasonic energy applied to a workpiece. As previously noted, line power (e.g., low-frequency electrical signal of about 50-60 Hz) is converted to a high frequency, high voltage electrical signal (e.g., 15-70 kHz, and more particularly 20-40 kHz). The high frequency electrical signal is then converted to a mechanical vibration at an ultrasonic frequency in a converter (i.e., transducer). An optional booster may be included in the system in order to amplify the mechanical vibration such that the vibration amplitude can be increased. The ultrasonic vibrations then propagate through anose horn 112. Anend face 136 of thenose horn 112 can then focus the ultrasonic vibration and deliver the vibration energy to a specified area on a material (e.g., at a portion of afirst workpiece 118 to be riveted). - With reference to
FIG. 4 , amethod 150 of joining first andsecond workpieces hybrid joining machine 100 ofFIGS. 3A through 3E . Specifically, atstep 152, the first andsecond workpieces die 116 such that the second,lower workpiece 120 rests directly on thedie 116 and the first,upper workpiece 118 rests on thelower workpiece 120, as shown inFIG. 3A . Atstep 154, thenose horn 112 is actuated by hydraulic pressure so as to behave as a retractable clamping cylinder for themachine 100. Thenose horn 112 is driven downwardly towards theupper workpiece 118 to urge theworkpieces die 116, as shown inFIG. 3B . It should be noted that other drive mechanisms may be used for driving thenose horn 112, e.g., an electrically powered screw assembly, an electrically powered actuator, or via a spring. - At
step 156, thenose horn 112 is excited with ultrasonic vibration so as to locally heat theworkpieces workpieces workpieces nose horn 112 and theworkpiece 118 and at the interface between theworkpieces heated material zone 132. Atstep 158, apunch 114, which is coaxially slidable within thenose horn 112, is actuated so as to drive arivet 122 into theupper workpiece 118. Thepunch 114 continues driving therivet 122 until therivet 122 penetrates the lower workpiece 120 (seeFIG. 3C ). In particular, thepunch 114 contacts ahead portion 124 of therivet 122 and pierces theupper workpiece 118 with ashank 126 of therivet 122 only partially piercing and entering, but not completely passing through the lower workpiece 120 (i.e., does not pass through the bottom surface of the lower workpiece 120). Notably, the localizedheated material zone 132 allows for enhanced riveting since stresses and friction in this material zone are reduced. - At
step 160, theshank 126 and the material of thelower workpiece 120 immediately adjacent to theshank 126 are deformed through interaction with thedie 116. The bottom surface of thelower workpiece 120 is subjected to the force of the die 116 as described herein such that the shape of the surface of thelower workpiece 120 is modified to conform to the shape of thedie 116. The complementary shape on thelower workpiece 120 mechanically interlocks theworkpieces FIG. 3D . - Furthermore, as the localized
heated material zone 132 cools, a fusedregion 134 is created at an interface between theworkpieces region 134 between the upper andlower workpieces region 134 contributes to the strength of the mechanical interface. The fusedregion 134 is most conveniently achieved if both theworkpieces workpieces region 134 should be considered representative of a wide range of fused areas that may result from this process. Depending on the duration and magnitude of application of the ultrasonic vibration, the extent of the fusedregion 134 may vary. However, to strengthen the interface and ease the insertion of therivet 122, at least a minimum localizedheated material zone 132 should be developed around the circumference ofshank 126. - At
step 162, thepunch 114 andnose 112 are withdrawn from the rivetedworkpieces workpieces FIG. 3E ). The assembledworkpieces - With reference now to
FIGS. 5A through 5E , an exemplaryhybrid joining machine 200 incorporates a hybrid joining technique involving the mechanical fastening of riveting with an electrode energy (i.e., Joule heat) applied to a workpiece. In this regard, an electrical power source may be connected to a die to create an electrical circuit that generates heat at a specified area on a material (e.g., at a portion of a workpiece to be riveted). - In particular, a lower electrode die 216 may be split into a
first portion 238, also referred to as an insulator (e.g., polymer, ceramic); asecond portion 240, also referred to as a first conductor (e.g., tungsten carbide); and awasher 242, also referred to as a second conductor (e.g., steel). Theinsulator 238 may be formed with thefirst conductor 240 to establish aninterior wall 244 of thedie 216. Thesecond conductor 242 may be arranged on anend surface 230 of thefirst conductor 240 so as to contact alower workpiece 220. Anelectrical power source 246 may be interconnected with thedie 216 at thefirst conductor 240, in order to selectively create an electrical circuit. The electrical circuit runs through the electrically conducting components of the assembly, namely from thefirst conductor 240 through thesecond conductor 242 and out again through thefirst conductor 240. The electrical energy running through thesecond conductor 242 locally heats thelower workpiece 220. - With reference now to
FIG. 6 , amethod 250 of joiningworkpieces hybrid joining machine 200 ofFIGS. 5A through 5E . Specifically, atstep 252, first andsecond workpieces die 216 such that the second,lower workpiece 220 rests directly on thedie 216 and the first,upper workpiece 218 rests on thelower workpiece 220, as shown inFIG. 5A . Atstep 254, thenose 212 is actuated by hydraulic pressure so as to behave as a retractable clamping cylinder for themachine 200. Thenose 212 is driven downwardly towards theupper workpiece 218 to urge theworkpieces die 216, as shown inFIG. 5B . It should be noted that other drive mechanisms may be used for driving thenose 212, e.g., an electrically powered screw assembly, an electrically powered actuator, or via a spring. - At
step 256, theelectrical power source 246 is initiated and electrical current flows through thefirst conductor 240 to thesecond conductor 242, around thesecond conductor 242, and back out through the opposite side of thefirst conductor 240, as depicted byarrows 248. The electrical current passing through thesecond conductor 242 locally generates joule heat, consequently heating theworkpieces workpiece 220 creating a localizedheated material zone 232. - At
step 258, apunch 214, which is coaxially slidable within thenose 212, is actuated so as to drive arivet 222 into theupper workpiece 218. Thepunch 214 continues driving therivet 222 until therivet 222 penetrates the lower workpiece 220 (seeFIG. 5C ). In particular, thepunch 214 contacts ahead portion 224 of therivet 222 and pierces theupper workpiece 218 with ashank 226 of therivet 222 only partially piercing and entering, but not completely passing through the lower workpiece 220 (i.e., does not pass through the bottom surface of the lower workpiece 220). Notably, the localizedheated material zone 232 allows for enhanced riveting since stresses and friction at least in this material zone are reduced. - At
step 260, theshank 226 and the material of thelower workpiece 220 immediately adjacent to theshank 226 are deformed through interaction with thedie 216. The bottom surface of thelower workpiece 220 is subjected to the force of the die 216 as described herein such that the shape of the surface of thelower workpiece 220 is modified to conform to the shape of thedie 216. The complementary shape on thelower workpiece 220 mechanically interlocks theworkpieces FIG. 5D . The electrical current from theelectrical power source 246 may then be removed in order to allow thematerial zone 232 to cool. As previously noted, to ease the insertion of therivet 222, at least a minimum localizedheated material zone 232 should be developed around the circumference ofshank 226. - At
step 262, thepunch 214 andnose 212 are withdrawn from the rivetedworkpieces workpieces FIG. 5E ). The assembledworkpieces - Embodiments of the present disclosure are described herein. This description is merely exemplary in nature and, thus, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for various applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.
Claims (20)
1. A joining device comprising:
a nose;
a punch coaxially slidable within the nose;
a fastener arranged within the nose, the fastener being coaxially slidable within the nose and movable by the punch; and
a die anvil, wherein an ultrasonic vibration is focused through the die anvil to a zone on a material assembly arranged thereon for heating the zone, and wherein the punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.
2. The joining device of claim 1 , wherein the material assembly includes a first and second workpiece and wherein the fastener is configured to join the first workpiece to the second workpiece.
3. The joining device of claim 2 , wherein the fastener further includes a head and a shank extending from the head, and wherein the punch contacts the fastener at the head and drives the shank through the first workpiece and into the second workpiece.
4. The joining device of claim 3 , wherein the die anvil has a die face that receives the second workpiece when the shank of the fastener is in the zone, and wherein the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces.
5. The joining device of claim 1 , wherein at least a portion of the zone on the material assembly is fused upon cooling of the zone.
6. A joining device comprising:
a nose horn;
a punch coaxially slidable within the nose horn;
a fastener arranged within the nose horn, the fastener being coaxially slidable within the nose horn and movable by the punch; and
a die having a material assembly arranged thereon, wherein the nose horn is axially movable to a position contacting the material assembly, wherein an ultrasonic vibration is focused through the nose horn to a zone on the material assembly for heating the zone, and wherein the punch is configured to drive the fastener outwardly from the nose horn and into the material assembly at the zone.
7. The joining device of claim 6 , wherein the material assembly includes a first and second workpiece and wherein the fastener is configured to join the first workpiece to the second workpiece.
8. The joining device of claim 7 , wherein the fastener further includes a head and a shank extending from the head, and wherein the punch contacts the fastener at the head and drives the shank through the first workpiece and into the second workpiece.
9. The joining device of claim 8 , wherein the die has a die face that receives the second workpiece when the shank of the fastener is in the zone, and wherein the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces.
10. The joining device of claim 6 , wherein at least a portion of the zone on the material assembly is fused upon cooling of the zone.
11. A joining device comprising:
a nose;
a punch coaxially slidable within the nose;
a fastener arranged within the nose, the fastener being coaxially slidable within the nose and movable by the punch; and
an electrode die, wherein an electrical current is focused through the electrode die to a zone on a material assembly arranged thereon for heating the zone, and wherein the punch is configured to drive the fastener outwardly from the nose and into the material assembly at the zone.
12. The joining device of claim 11 , wherein the electrode die further comprises:
an insulator;
a first conductor arranged about the insulator; and
a second conductor arranged on an end surface of the first conductor, the second conductor configured to contact the material assembly.
13. The joining device of claim 12 , wherein the insulator is one of a ceramic and a polymer.
14. The joining device of claim 12 , wherein the first conductor is a tungsten carbide.
15. The joining device of claim 12 , wherein the second conductor is a steel.
16. The joining device of claim 11 , wherein the material assembly includes a first and second workpiece and wherein the fastener is configured to join the first workpiece to the second workpiece.
17. The joining device of claim 16 , wherein the fastener further includes a head and a shank extending from the head, and wherein the punch contacts the fastener at the head and drives the shank through the first workpiece and into the second workpiece.
18. The joining device of claim 17 , wherein at least a portion of the zone on the material assembly is fused upon cooling of the zone.
19. The joining device of claim 17 , wherein the shank of the fastener is deformed to create a mechanical joint with the first and second workpieces.
20. The joining device of claim 16 , wherein an electrical power source is interconnected with the electrode die to selectively create an electrical circuit for conducting electrical current through the first and second conductors, wherein the electrical current at the second conductor locally heats the second workpiece.
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/348,595 US20180126445A1 (en) | 2016-11-10 | 2016-11-10 | Hybrid workpiece joining |
CN201711058652.0A CN108067579A (en) | 2016-11-10 | 2017-11-01 | Mix workpiece connection |
DE102017126117.6A DE102017126117A1 (en) | 2016-11-10 | 2017-11-08 | COMBINING A HYBRID WORKPIECE |
US15/957,976 US20180236528A1 (en) | 2016-11-10 | 2018-04-20 | Hybrid workpiece joining |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US15/348,595 US20180126445A1 (en) | 2016-11-10 | 2016-11-10 | Hybrid workpiece joining |
Related Child Applications (1)
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US15/957,976 Division US20180236528A1 (en) | 2016-11-10 | 2018-04-20 | Hybrid workpiece joining |
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US20180126445A1 true US20180126445A1 (en) | 2018-05-10 |
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Family Applications (2)
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US15/348,595 Abandoned US20180126445A1 (en) | 2016-11-10 | 2016-11-10 | Hybrid workpiece joining |
US15/957,976 Abandoned US20180236528A1 (en) | 2016-11-10 | 2018-04-20 | Hybrid workpiece joining |
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US15/957,976 Abandoned US20180236528A1 (en) | 2016-11-10 | 2018-04-20 | Hybrid workpiece joining |
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US (2) | US20180126445A1 (en) |
CN (1) | CN108067579A (en) |
DE (1) | DE102017126117A1 (en) |
Cited By (1)
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---|---|---|---|---|
CN112974714A (en) * | 2019-12-17 | 2021-06-18 | 财团法人金属工业研究发展中心 | Method for joining sheet metal parts and for cooling same |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
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KR20230019842A (en) * | 2020-06-03 | 2023-02-09 | 쿨리케 앤드 소파 인더스트리즈, 인코포레이티드 | Ultrasonic welding systems, methods of using them, and related works including welded conductive pins |
CN114160745B (en) * | 2021-12-03 | 2022-10-14 | 眉山中车紧固件科技有限公司 | Short tail structure fastening connection system and installation method thereof |
CN114406110B (en) * | 2022-01-24 | 2022-12-16 | 深圳职业技术学院 | Pressure riveting method and pressure riveting device |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2015107350A1 (en) * | 2014-01-16 | 2015-07-23 | Henrob Limited | Method of riveting |
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GB9226517D0 (en) * | 1992-12-19 | 1993-02-10 | Henrob Ltd | Improvements in or relating to sefl-piercing riveting |
US6694597B2 (en) * | 2002-03-08 | 2004-02-24 | General Motors Corporation | Method for riveting metal members |
KR100501655B1 (en) * | 2003-04-18 | 2005-07-18 | 현대자동차주식회사 | Self Piercing Friction Rivet for Aluminum and Joining methond of Aluminum Sheets |
US6864571B2 (en) * | 2003-07-07 | 2005-03-08 | Gelcore Llc | Electronic devices and methods for making same using nanotube regions to assist in thermal heat-sinking |
US8250728B2 (en) * | 2008-07-28 | 2012-08-28 | GM Global Technology Operations LLC | Method of joining with self-piercing rivet and assembly |
CN101817142A (en) * | 2010-05-20 | 2010-09-01 | 上海交通大学 | Self-piercing frictional rivet welding connecting device |
US10189113B2 (en) * | 2014-04-24 | 2019-01-29 | GM Global Technology Operations LLC | Resistance spot welding method |
-
2016
- 2016-11-10 US US15/348,595 patent/US20180126445A1/en not_active Abandoned
-
2017
- 2017-11-01 CN CN201711058652.0A patent/CN108067579A/en active Pending
- 2017-11-08 DE DE102017126117.6A patent/DE102017126117A1/en not_active Withdrawn
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2018
- 2018-04-20 US US15/957,976 patent/US20180236528A1/en not_active Abandoned
Patent Citations (1)
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WO2015107350A1 (en) * | 2014-01-16 | 2015-07-23 | Henrob Limited | Method of riveting |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN112974714A (en) * | 2019-12-17 | 2021-06-18 | 财团法人金属工业研究发展中心 | Method for joining sheet metal parts and for cooling same |
Also Published As
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CN108067579A (en) | 2018-05-25 |
DE102017126117A1 (en) | 2018-05-17 |
US20180236528A1 (en) | 2018-08-23 |
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