Investigation of the influence of varying tumbling strategies on a tumbling self-piercing riveting process

Abstract The increasing demands for the reduction of carbon dioxide emission require intensified efforts to increase resource efficiency. Especially in the mobility sector with large moving masses, resource savings can contribute enormously to the reduction of emissions. One possibility is to reduce the weight of the vehicles by using lightweight technologies. A frequently used method is the implementation of multi-material systems. These consist of dissimilar materials such as steel, aluminium or plastics. In the production of these systems, the joining of the different materials and geometries is a central challenge. Due to the increasing demands on the joints, the challenges for the joining processes itself are also increasing. Since conventional joining processes are rather rigid and can only react to a limited extent to disturbance variables or changing process variables, new methods and technologies are required. A widely used conventional joining method with these properties is self-piercing riveting. Because of the rigid tool combination and the fact that the rivet geometry that can be used is related to the tools, the joining of multi-material systems requires tool and rivet changes during the process. In order to extend the process window of joining with self-piercing rivet elements, the process is enhanced with a tumbling kinematic of the punch. The integration of tumbling results in a significant increase in the adjustable process parameters. This enables a higher material flow control in the joining process through a specific tumbling strategy. The materials investigated are a steel and an aluminium alloy, which differ significantly in their mechanical properties and have many applications in automotive engineering, especially for structural car body components. The steel material is a galvanized HCT590X+Z dual-phase steel, which is characterised by a low yield strength, combined with high tensile strength and a good hardening behaviour. The aluminium alloy is an EN AW-6014. The precipitation-hardening alloy consists of aluminium, magnesium and silicon with a high strength and energy absorption capability. The objective of this work is to obtain a fundamental knowledge of the new tumbling self-piercing riveting process. With different mechanical properties and different sheet thicknesses of the joining partners, the influences of these parameters on the tumbling strategy of the riveting process are analysed. Such a tumbling strategy is based on the tumbling angle, the tumbling onset and the tumbling kinematics. These parameters are investigated in the context of the work for selected combinations of multi-material systems consisting of HCT590X+Z and EN AW-6014. With the variation of the parameters, the versatility of the process can be investigated and influences of the tumbling on the self-piercing riveting process can be identified. To illustrate the results, force–displacement curves from the joining process of the individual joints are compared and the geometry of the rivet undercut and rivet heads are geometrically measured. Furthermore, micrographs allow the analysis of the characteristic joint parameters interlock, residual sheet thickness and end position of the rivet head

Joining by forming technologies: current solutions and future trends

The progressively more demanding needs of emissions and costs reduction in the transportation industry are pushing engineers towards the use of increasingly lightweight structures. This goal can be achieved only if dissimilar and/or new materials, including polymers and composites, are joined together to create complex structures. Conventional fusion welding processes have often been proven inadequate to this task because of the high heat input reducing the joint mechanical properties or even making the joining process impossible. Joining by forming technologies take advantage on the plastic deformation to create sound joints out of even very dissimilar materials. Over the last 25 years, several new processes, with increasing potential in effectively joining virtually every structural material, have been invented and developed. In the paper, a comprehensive overview of the most utilized joining by forming processes is given. For each process, an analysis of the current research trends and hot topics is provided, highlighting strengths and weaknesses for industrial applications

Data acquisition and control at the edge: a hardware/software-reconfigurable approach

Abstract Today’s manufacturing facilities and processes offer the potential to collect data on an unprecedented scale. However, conventional Programmable Logic Controllers are often proprietary systems with closed-source hardware and software and not designed to also take over the seamless acquisition and processing of enormous amounts of data. Furthermore, their major focus on simple control tasks and a rigid number of static built-in I/O connectors make them not well suited for the big data challenge and an industrial environment that is changing at a high pace. This paper, advocates emerging hardware- and I/O reconfigurable Programmable System-on-Chip (PSoC) solutions based on Field-Programmable Gate Arrays to provide flexible and adaptable capabilities for both data acquisition and control right at the edge. Still, the design and implementation of applications on such heterogeneous PSoC platforms demands a comprehensive expertise in hardware/software co-design. To bridge this gap, a model-based design automation approach is presented to generate automatically optimized HW/SW configurations for a given PSoC. As a case study, a metal forming process is considered and the design automation of an industrial closed-loop control algorithm with the design objectives performance and resource costs is investigated to show the benefits of the approach

Extreme Ultraviolet Wave Packet Interferometry of the Autoionizing HeNe Dimer

Femtosecond extreme ultraviolet wave packet interferometry (XUV-WPI) was applied to study resonant interatomic Coulombic decay (ICD) in the HeNe dimer. The high demands on phase stability and sensitivity for vibronic XUV-WPI of molecular-beam targets are met using an XUV phase-cycling scheme. The detected quantum interferences exhibit vibronic dephasing and rephasing signatures along with an ultrafast decoherence assigned to the ICD process. A Fourier analysis reveals the molecular absorption spectrum with high resolution. The demonstrated experiment shows a promising route for the real-time analysis of ultrafast ICD processes with both high temporal and high spectral resolution

Review on mechanical joining by plastic deformation

Mechanical joining technologies are increasingly used in multi-material lightweight constructions and offer opportunities to create versatile joining processes due to their low heat input, robustness to metallurgical incompatibilities and various process variants. They can be categorised into technologies which require an auxiliary joining element, or do not require an auxiliary joining element. A typical example for a mechanical joining process with auxiliary joining element is self-piercing riveting. A wide range of processes exist which are not requiring an auxiliary joining element. This allows both point-shaped (e.g., by clinching) and line-shaped (e.g., friction stir welding) joints to be produced. In order to achieve versatile processes, challenges exist in particular in the creation of intervention possibilities in the process and the understanding and handling of materials that are difficult to join, such as fiber reinforced plastics (FRP) or high-strength metals. In addition, predictive capability is required, which in particular requires accurate process simulation. Finally, the processes must be measured non-destructively in order to generate control variables in the process or to investigate the cause-effect relationship. This paper covers the state of the art in scientific research concerning mechanical joining and discusses future challenges on the way to versatile mechanical joining processes