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TOX®-Joining-Systems
TOX®-Round JointTOX®-SKBTOX®-Flat JointTOX®-MICROpointTOX®-TWINpointTOX®-Vario JointTOX®-ClinchRivet
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The TOX®-Joining SystemsThe best answer to every challenge
Why a new technique?Because all previous methodshave involved economic and tech-nical problems. Take welding, forexample. A complex, expensiveprocess which can only beapplied to precoated sheet metalor aluminium with great difficulty.Surface coatings are damaged orsheet metals are not joined pro-perly. And there is still no reliableautomatic process control for allthese imponderable factors.
The TOX®-Joining Technique putsan end to these problems. It joinsdifferent materials by means of adeep drawing-pressing process.And it does so without damage tothe surface, purely by displacingand forming.
Practice has alreadyshown the benefits ofTOX®-Joining, bothtechnically and eco-nomically.
Dr. Rudolf Eberle innovation prizefor exemplary achievement.
Side part of a seat
Sun roof frame
Hand brake lever
Engine mountEngine bonnet Brake disk covering
Home appliances: Joining prepainted sheet metalmade possible with TOX® PRESSOTECHNIK!
PC housings: The TOX®-Joint reservesthe anticorrosive surface coating.
Kitchen drawer slides
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See for yourself:
+ TOX®-Round Joint: 30 to 60 %cost savings as comparedto spot welding.
+ The TOX®-Joint achieves up to 70 %of the static strength of a spot weld.
+ The dynamic strength of TOX®-Joint is higher than in spot welding.
+ The joining process can be automat-ically monitored and documented.
+ Simple, non-destructive quality control is possible.
+ The materials are strain hardenedat the connecting joint and aretherefore stronger compared tospot welding, which has significantstresses around the weld nugget,the TOX®-Joint does not exhibitany metallurgical residual effects.
+ Optimal corrosion resistance withgalvanized and prepaintedmaterials, since the protectivelayer flows with the material.
+ Perfect joints are producedeven with narrow flanges andsmall mounting spaces.
+ Outstanding conductivity forelectric components.
+ Cold forming process is ideal for hybrid connections (gluing and clinching).
+ The TOX®-Round Joint can carryshear and pull stress loads, in-dependent of the load orientation.
Convincing features:
+ The TOX®-MICROpoint isespecially applicable for verythin metal sheets.
+ The TOX®-TWINpoint:The non-rotating TOX®-TWINpoint with excellent electrical conductivity characteristic.
+ TOX®-ClinchRivet:Comparable strength to self-piercing rivets but without cutting the sheet metal layers.
Seat rail
Window lifter
Advantages for a good connection
For each operation a suitablesolution:
• Point diameter from 1.5 to 26 mm
• Individual sheet thicknessesfrom 0.1 to 11 mm
• 2 – 4 sheet metal layers
• Hybrid connections(steel/glue/aluminium)
• Extensive know-how
• Worldwide service
How may we help you?
With our TOX®-TestReport we guaranteeour technology.
Zinc coated parts:With TOX®-Joint,the coatingremains intact!
Gas meter housing: TOX®-Joints are leakproof. Miniature relay contacts:
Securely joined withTOX®-MICROpointØ 2 mm.
TOX®-Roun
d Joints hav
e by far
the best elec
trical conduc
tivity in
comparison
to other mec
hanical
joining techn
iques
Source: TU D
resden, repor
t of the group
Joining
as of 2012
4
2
. . . . . . . . . . . .
Einzelblechdicke ts = tm (mm)
Fs
,F
k(N
)
2
. ,
. ,2
. ,
2
. ,
. ,2
. ,
2
. ,
X-M
aß
(mm
)
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TOX®-TechnologyClinching facts
The strength behind the TOX®-JointIn the TOX®-Round Joint process,the material strain hardening in theneck area and the lacking of anynotch effects produce the highretaining forces. This is the directresult of the fixed, rigid die. For thisreason, even the TOX®-SKB Die hasfixed segments.
The TOX®-ClinchRivet process com-bines the advantages of the RoundJoint with those of a riveting process.
FlexibilityThe same tool set can be used tojoin sheet metals of different sheetthicknesses. The tool set suitable forthe application is determined in theTOX®-Test Report which guaranteesthe required holding forces.
Durability Static strength up to 70 % of a spotweld, with positive strain hardening,without damage to the surface coat-ing, and typically more economical.Isn’t all this worth looking at?
Fatigue strength under the mostadverse conditionsCorrosion tests have shown thatbecause the surface coating is notdamaged during the round jointprocess, the anti-corrosive proper-ties of the joined sheet metals, e.g.,aluminized or galvanized, are main-tained. The TOX®-Joining-Systemdoes not cut the surface of thematerials to be joined, as the coat-ing flows with the material andremains intact.
The dynamic strength is higherthan in spot weldingAdvantageous dynamic strengthwithout notch effect in the joint – thismeans: The life of the TOX®-RoundJoint lasts much longer than that ofa weld point.
On the right:The TOX®-Joint in customer testResults of endurance tests for sam-ples with TOX®-Round Joints andspot welds. The joints were exposedto an initial load of 1 kN and a fre-quency of approximately 35 Hz. Thefatigue life of the joint was measureduntil failure.
Test series standard tool set(without tool change)
Fs, Fk (N) Control dimension X (mm)
Surface: as-rolled tp= punch sideMaterial: DC01 (CRS) td= die side
2.25
2
1.75
1.5
1.25
1
0.75
0.5
0.25
0
4500
4000
3500
3000
2500
2000
1500
1000
500
0
This is how a TOX®-Joint isformed
• Penetration• Interlock formation of punchside sheet metal
• Completed TOX®-JointForce apmlitude Fa
2000
1500
1000
500
Joined samples, vapour degreasedFD,100%
280 N Spot welding
Clinching, star shape
FD = fatigue strength
TOX®-Round Joint
250 N
560 N
103 104 105 106 107 108
Number of cycles N
20s
F
Source: EFB (German Research Group) research report No. 37
DC04/s= 0.8 mm
1 2 3 4
9
8
7
6
5
4
3
2
1
0
with ageing1000-hr-salt spray test1000-hr-climate test
1.00 1.25 1.55 1.75 2.15 2.55
Corrosion testShear forceFs in kN
TOX®-Round Joint 6 mm
TOX®-ClinchRivetTOX®-Round Joint
1 =material = DC04 (crs)Individual sheet thicknesst = 0.8 mmvapour degreased
2 =material = DC04 (crs)t = 0.8 mm adhesive film
3 =material = DC04 (crs)t = 0.8 mm edge-formedseam adhesive paste
4 =material = ENAW-5182vapour degreased
Cross tension Fk
Dimension X
Shear tension Fs
Single sheet metal thicknesstp = td (mm) ts = tm (mm)
5
2800
2600
2400
2200
2000
1800
1600
1400
1200
1000
450
400
350
300
250
200
150
100
50
0
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160.000
140.000
120.000
100.000
80.000
60.000
40.000
20.000
0
t = < 1,0 t = 1,0 – 1,2 t = 1,3 – 1,5 t = 1,6 – 2,0
normaler Standmengenbereich
Einzelblechdicken (mm)
Anz
ahl F
ügep
unkt
e / S
atz
Werkzeugstandmengen bei EdelstahlBlechwerkstoff: 1.4301 ölig / TOX®-Punkt 8,0 mm
TOX®-TechnologyThe advantage for you and the environment:cost effective and efficient
TOX®-Joining: the simple processcuts your manufacturing costs.
The system efficiency and the ser-vice life of the tools are closely inter-dependent.
(1) shows a cost comparison for thesingle joint technique between spotwelding and TOX®-Joining for a mildsteel application. The TOX®-Joining-System can be used in multipointapplications, which can increaseconsiderably the cost differencebetween TOX®-Joining and spotwelding.
(2) shows the normal service life ofTOX®-Tools. The given values andguidelines depend on the particularapplication.
TOX®-ClinchRivetThe TOX®-ClinchRivet is a logicalfurther development of the TOX®-Round Joint. By filling the joint withthe rivet, the TOX®-ClinchRivetprocess increases the joint strengthconsiderably, especially the shearstrength. Higher strength can beachieved when compared to piercerivets, especially with thin sheet metals. It is important to mentionthat with TOX®-ClinchRiveting, theupper sheet metal layer will not becut: No risk of corrosion.
Joining of stainless steelStainless steel presents specialrequirements for forming processes.The required higher forming forcesresult in higher surface stresses onthe joining tools. The TOX®-JoiningTechnology can be used safely andefficiently even for stainless steelapplications. Continuous tool devel-opment and experience with manyapplications have resulted in hightool life.
t = < 1.0 t = 1.0 – 1.2 t = 1.3 – 1.5 t = 1.6 – 2.0
normal tool life range
Individual sheet metal thickness [mm]
160.000
140.000
120.000
100.000
80.000
60.000
40.000
20.000
0Number of joints before tool change
Tool life with stainless steelSheet metal material: stainless steel 1.4301 (A/SI 304) oily / TOX®-Point 8.0 mm
Material
500 000
400 000
300000
200 000
100 000
Steel
normal tool life range
(2) Number of TOX®-Joints until tool change
AluminiumSteelgalvanizedprepainted
Customers have alreadyachieved much higher tool life.
Mean value Fs in NMean value Fk in NTensile strength Shear strength
Retainingforce in N
Type of joint
Comparison of joint strength for various joining at AC120 1.25 mm into 1.25 mm
TOX®-ClinchRivet Pierce rivet X Pierce rivet Y
Cost per 100.000 joints in Euro
Tooling Operating costs Investment
TOX®-Joining Spot welding
(1) Cost per joining
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The TOX®-Joining-SystemsSimplicity is our strength
The patented TOX®-Round Joint is the core of our techno-logy. A simple round punch presses the materials to be joi-ned into the die cavity. As the force continues to increase,the punch side material is forced to spread outwards withinthe die side material. The result: An aesthetically pleasinground button, which joins clearly without any burrs or sharpedges on which corrosion could set in. Even with aluminizedor galvanized sheet metals, the anti-corrosive propertiesremain intact as the protective layer flows with the material. The electrical conductivity is excellent.
TOX®-Round Joint
The TOX®-Round Joint:Smart joining technology with noadded fastenersIncreasing strength:The materials are plasticallydeformed in the joining area, there-fore, increasing the strength. Thereare no stress concentration factors.The advantages of the TOX®-Join-ing-System can also be appreciatedin regards to the environment –particularly in comparison to weld-ing. Just think of welding alumini-um, galvanized or prepainted sheetmetal!Cutting costs Besides the directly measurablecost advantages, considerablesavings can also be made with amuch simpler production sequence.For example, it is often possible topunch, bend and join in one pro-gressive die. This saves an entireworking cycle as well as transporta-tion to the joining station – or weld-ing shop. Which is a great advan-tage in terms of logistics.
Process sequence
The TOX®-TWINpoint provides protection against rotationand, in comparison to the single joint, clearly increases thejoint strenght.The TOX®-TWINpoint has an excellent electrical conductivitycharacteristic. A solid die and the same process as for thesingle joint guarantee the full advantages of the TOX®-Round Joint. The TOX®-TWINpoint is ideal for small flangesand limited installation space.
The miniature TOX®-Round Joint with point diameters of1.5 to 2 mm is the answer to the miniaturization of compo-nents. It is ideal for sheet metal thicknesses from 0.1 –0.5 mm and narrow flanges. The electrical conductivity bet-ween the joined layers is outstanding.
TOX®-TWINpoint
TOX®-MICROpoint
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In some instances, the button formed by the TOX®-Point may be undesirable.That’s why we developed theTOX®-Flat Joint and the TOX®-SKB Flat.
TOX®-Flat Joint / TOX®-SKB Flat
Forming the TOX®-Flat Joint:• The first step is to produce thestandard TOX®-Round Joint orTOX®-SKB.
• The resulting button is flattened(± 0.1 mm) in a secondary ope-ration.
The high shear and pull strengthsof the TOX®-Point are left virtuallyintact.
Process sequence
A special clinch-die has solid and flexible segments.The materials and the punch are centered by the fixedsegments, thereby guaranteeing that the joint formationis perfectly concentric. The mobile elements between thesolid segments allow an interlocking of the material in thejoint.
TOX®-SKB
The advantages are seen in amore flat protrusion of the jointand a higher flexibility when sheetmetals of different thickness haveto be joined with one tool set.
The special arrangement of thesprings allows extremely slendertools and thus better accessibilityand minimal interference com-pared with conventional die con-struction without solid part.
The TOX®-SKB Die shows itsstrength specially when glue isused between the sheet metal layers. Furthermore, it has been successfully implemented for theTOX®-ClinchRivet (see page 8).
Process sequence
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Specialities of the technology
Process sequence
The TOX®-Point for difficult cases: Joining of sheet metalwith large differences in thickness, joining of high strength ornon ductile materials with ductile materials or joining of nonmetallic materials.Characteristics: One layer is pre-punched, the ductilematerial is then pushed through the hole. The connectionhas radial and axial strength. Multiple joints can be appliedin a single press stroke. This process requires precisealignment of the parts.
TOX®-Vario Joint I TOX®-Vario Joint II
In the case of the patented TOX®-ClinchRivet, the actualrivet joining is made from a simple cylinder rivet in a joiningprocess using drawing/pressing methods. Similar to theTOX®-Round Joint, the material to be joined is not cut butled through the die form thus producing a very resistantjoint – also in the case of thin materials.
Multijoint applications increase cost advantages.
TOX®-ClinchRivet
The special advantage of the TOX®-ClinchRivet is the simple, symme-trical and inexpensive rivet. Thisresults in the troublefree feed andcompression. The materials to bejoined gain an additional retainingcomponent. A clean and highlyreproducible joint is created.
All technological characteristicsand quality criteria of the TOX®-Round Joint also apply to theTOX®-ClinchRivet.
Process sequence
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TOX®-StandardsThe modular program – flexible and field-proven
TOX®-Tools
TOX®-Flat Plate DieOffers unbeatable accessin hard to reach corners.
TOX®-Tool HolderWith integrated stripper
TOX®-Robot- and Machine TongsWith pneumo-hydraulic, electricor hydraulic drive.
TOX®-PressesWith integrated mulitpoint diesets, safety equipment, controlsystem and process monitoringOur know-how, your benefit.
TOX®-Die SetsThe most economical way to useTOX®-Joining. Multiple points canbe produced in one operation.
TOX®-PowerKurverFor simultaneousclamping and joining. No need for repeated clamping andfixturing. Optimal accessibility for largepanels due to > 90° operating angle.With pneumatic or electric drive.
TOX®-HandheldTongsThe suspensionoffers an optimumhandling.
TOX®-Tongs FixturesIn single and multipoint design,specially adapted to your component.They are pneumatic, pneumo-hydraulic or hydraulic driven.
TOX®-ClinchRivetStandardized swage heads includingfeed and fill level control. For use insingle and multijoint applications.Appropriate for robots.
TOX®-FinePressHigh-quality benchtop presses –compact and perfect.
10
KN
30
25
20
15
10
5
07 6 5 4 3 2 1 0
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The specially adapted process moni-toring system for the TOX®-JoiningTechnique helps you to check thecompetitive factor of quality:• For each produced component• For each clinch point in thecomponent
A cost effective production monito-ring for short cycle times requires acontrol system which is integrated intothe line – in short, a system like theTOX®-Process Monitoring System.
The TOX®-Process Monitoring Systemguarantees your quality standards, not only for mass production, butalso for small-scale manufacturing.
TOX®-Process Monitoring keeps a constant check on your clinch points.
Functional principle:Force sensors measure the press for-ce at the clinch points. A position indi-cator monitors the attainment of con-trol dimension X (quality dimension).Once the position indicator signalsthat control dimension X has been
reached, the press forces measuredby the load cells are compared withthe nominal press forces. The TOX®-Point is satisfactory if the measuredpress force lies within the preset tole-rance range. Thus, it is possible tomake an assessment on material
type, strength and thickness, right toolcombination as well as tool failure ormissing layer of sheet metal.As alternative it is possible to evalua-te the complete force-travel-characte-ristic curve (EPW 400 measuring prin-ciple).
Resistance to pull and shear loads isdependent on the control dimension X,provided that the joining parametersand the service life of the tools havebeen observed.
Evaluation units for monitoring of clinch processes
- Force monitoring of clinching processes- Trend monitoring- Process sequencing- Network capability over Ethernet TCP/IP- Expandable to userdefined processes- With and without display
TOX® -Process Monitoring CEP 400/400T
TOX®-ToolCheck pneumatic testing of clinching dies
The evaluation device can be selec-ted according to each requirement.From 1- to 12-channel clinch monito-ring all the way to continuous measu-ring in force-travel-pressing monito-ring.
Various evaluation methods allow fordifferent analysis of your processes.Diverse communication interfacesallow for simple and quick data trans-fer to the data storage.
Control dimension X (mm)
Punch
Compres-sed Air
Stripper
Die
TOX®softWareEthernet
Interbus/ProfiNet/ProfibusRS 232/485
PLC
TOX®-Monitoring
NETWORK
The die monitoring system TOX®-ToolCheck, together with the processmonitoring, checks the condition ofthe TOX®-Clinching Dies. This ensu-res that the joining process is alwaysperformed with an intact die. Anypoten-tial defects, like missing or (e.g.by contamination) jammed movingelements of the TOX®-SKB Die, aswell as ruptures on either the solid
TOX®-Die or on the fixed segments ofSKB, are identified within < 1 second.
+ Optimum tool life quantity+ Increase production reliability+ Maximum tool life usage
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Controlled precision clinchingusing electric drives
set point
envelope
target window
Point diameterPoint diameter
Controldimension "X"Controldimension "X"
de
With the introduction of the solidpunch riveting technology anothersolely mechanical joining method isadded to the portfolio of TOX®-SheetMetal Joining Systems. Solid punchriveting has its preferred applicationsin the field of automotive lightweightconstructions, respectivly for the join-ing of hybrid components and assem-blies of alternative materials.The complete solutions include theknow-how, the competence and the
equipment for all solid punch rivetingrequirements: the technology, thetooling, presses and riveting devices,single or multiple rivet supply lines,controls. The rivet placing can be accom-plished by c-bow or column presses,handheld or robot tongs as well as bycustom made devices and machines.
TOX®-Joining Systems for solid punch rivets
Typical shape of a solid punch rivet
The control dimension X
In case of TOX®-Clinching, the con-trol dimension X describes the remai-ning bottom thickness after havingjoined two or more sheet metals witha clinching point.
TOX®-Robot Tongs and axis controller
Display of envelopes in theTOX®
softWare
TOX®softWare – Input of parameters
dicrectly on screen
Process monitoring using envelo-pes
The line-X axis controller additionallyprovides process monitoring func-tions via an envelope combination.
With this, the force/travel course ofjoining/pressing or clinching proces-ses can be completely monitored anddocumented.
The recorded force/travel characteri-stic must not leave the predefinedcorridor.
TOX®softWare = Simply good!
With the TOX®-ElectricDrive servodrives and the TOX®-Process Monito-ring units, the TOX®
softWare is inclu-ded in the delivery by default.
All processes can be parameterizedor automatically teached-in via theuser friendly user.
No programming knowledge is requi-red!
The control dimension X is easilyaccessible and is therefore an idealdimension for estimating the quality ofthe clinch joining. It is shown in theTOX®-Test Report which defines allprocess parameters.
Everything under control when joi-ning
Using the line-X axis controllers fromthe TOX®-ElectricDrive program andthe software modules especially deve-loped for this program, the controldimension X is guaranteed indepen-dent of any fluctuations regardingsheet thickness, strength and frictionconditions. Here, an accuracy of ± 0.04 mm is realized.The combination of flexibility, precisi-on and minimum setup times is stun-ning.
Typical application
TOX®-Robot Tongs for clinchingtasks with electromechanical driveTOX®-ElectricDrive and axis control-ler including TOX®
softWare.
If the envelope is violated, you candecide whether:
the process should be continued until the target window is reached.the process should be interruptedimmediately.
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Our Worldwide Sales and Service Network
80.201303.en Subject to technical alterations.
TOX®-ProductionSystems
TOX®-Press-Fitting
TOX®-Punching
TOX®-Coining
TOX®-Tongs
TOX®-Joining-Systems
TOX®-Controls
TOX®-Monitoring
TOX®-Presses
TOX®-FinePress
TOX®-ElectricDrive
TOX®-PowerKurver
TOX®-Powerpackage
Product Range
TOX® PRESSOTECHNIKRiedstrasse 4D-88250 WeingartenTel. +49 (0) 7 51 / 50 07-0Fax +49 (0) 7 51 / 5 23 91E-Mail: [email protected]
GMBH &CO. KG
