Mechanical Joining of Composites in High Volume Production · PDF fileNext Generation Fastener...

Next Generation Fastener Technology

Andreas Lembach

Mechanical Joining of Composites in High Volume Production

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GALM Series, Automotive Lightweight Materials Manufacturing Congress Europe, Birmingham, 2016.

M.Sc.(TU) Dipl.-Ing.(FH) Int. Welding Eng.(IWE) Andreas Lembach

Technical Development PROFIL Verbindungstechnik GmbH & Co.KG

Next Generation Fastener Technology

Andreas Lembach

Content

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- Company Background- Motivational Design example- General Issues with composites- Solutions

• Running• Developing• Brand new

Next Generation Fastener Technology

Andreas Lembach

PROFIL: Your system supplier for pierce nuts and studs

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Andreas Lembach

Example of a typical PROFIL Solution

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Andreas Lembach

Joining of two composite panels with nut and bolt

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strain

FF

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Andreas Lembach

Design example

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PA6 max surface pressure --> 80 N/mm²-wet, warm, reducing creep --> 5 N/mm²M8 nut/bolt max load (class 8 / 8.8) --> 21 kN--> Necessary washer diameter --> ~40 mm

Washer deformation

2,1 t

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Andreas Lembach

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[Schürmann, Konstruieren mit Faser-Kunststoff-Verbunden]

surface pressure [N/mm²]

Increasing washer thickness

Washer design balance

Worst case scenario

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Andreas Lembach

General Issues with Composites

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- Corrosion- Viscoelasticity (Creep)- Cutting Fiber/ Cutting Material- Delamination- Small bearable surface pressure- Variety of production processes- Variety of material properties- Anisotropic Material properties

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Andreas Lembach

Recommendation in literature for the connection of two panels:

Rivet joint

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[Schürmann, Konstruieren mit Faser-Kunststoff-Verbunden]

Recommendation in literature for threaded application: Bonding fastener

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Andreas Lembach

Rivet joint with thread --> rivet nut

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Andreas Lembach

Comparison with bonding

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Force transmission through rivet directly through all layers of material

Force transmission through flange, layer of glue and layer of matrix material before first layer of fibers

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KZB Fastener for bonding or laminating

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Warm hole forming

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Top View

Side View

2.Step riveting

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Andreas Lembach

1 2

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RSP warm hole forming and riveting in one step

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Andreas Lembach

KSB SBF RSF in two steps

15Cold punching and riveting

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Andreas Lembach

SBF - stud

Composite

Washer

Die button

Selfpiercing SBF in Composite in one step

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Andreas Lembach

Stainless Steel Bolt

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- Marine grade material - Food industry- Chemical industry - Corrosion resistance - Cold forging --> cost effective production

in stainless steel metal sheetin Carbon reinforced material

Aluminum Steel with special zinc coat Stainless Steel

12 weeks salt spray + temp variation

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Andreas Lembach

Applications in Research projects

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University Aachen, Germany-Inprolight-

Fraunhofer, Germany-Eprofit-

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Applications in Industry

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Mercedes: trunk Porsche: rear shelf

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Problem: Delamination

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Others: Self piercing rivets

PROFIL: SBV Solid rivet with washer

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Andreas Lembach

SBV – piercing material with preload

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• No cleaning or preperation of surface necessary.• Ultimate strength immediately available• Reliable process.• Good crash performace.• All BIW Materials• Independent of the stack thickness

Next Generation Fastener Technology

Andreas Lembach

SBV – piercing material with preload

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• No cleaning or preperation of surface necessary.• Ultimate strength immediately available• Reliable process.• Good crash performace.• All BIW Materials• Independent of the stack thickness

Next Generation Fastener Technology

Andreas Lembach

Next Generation Fastener Technology

Andreas Lembach

Next Generation Fastener Technology

Andreas Lembach

Next Generation Fastener Technology

Andreas Lembach

Thank you for your attention

See you at our booth

26GALM Series, Automotive Lightweight Materials

Manufacturing Congress Europe, Birmingham, 2016.