Skip to main content
SpringerLink
Log in

Combining a high-speed mechanical joining technique with the attachment of functional elements in automotive structures

  • Research Paper
  • Published:
Welding in the World Aims and scope Submit manuscript

Abstract

The implementation of lightweight materials such as modern wrought aluminium and casting alloys enables a significant reduction of the vehicle’s total mass. The extended use of lightweight aluminium castings and extrusions offers considerable potential for weight reduction. The cost-effective joining of these aluminium structures is challenging the conventional thermal and mechanical joining techniques. The paper details the development of a new type of mechanical functional element based on the principle of high-speed joining. Functional elements also know as fuctional attachments are normally attached separately from the fixings which used to join two or more sheets of material. Examples for fuctional elements are brackets, clips and fixing studs. The objective on this paper based project is the further development of the high-productive joining method high-speed joining to integrate a functional element into the joining process. For this, a modification of a given joining element geometry has to be developed that allows the transmission of high-torque moments and reaches high-push-out forces. Therefore, several geometries were developed and optimised with simulations and experimental investigations. The results show that the joining element based on the technology of high-speed joining can meet the requirements of metric aluminium stud-threads with diameters up to 6 mm and steel stud-threads with diameters up to 5 mm.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Meschut, G.; Janzen, V.; Olfermann, T. (2014) Innovative and highly productive joining technologies for multi-material lightweight car body structures. J Mater Eng Perform 05/2014, S. 1515–1523

  2. Mori K, Bay N, Fratini L, Fabrizio Micari A (2013) Erman Tekkaya, Joining by plastic deformation. CIRP Ann 62(2):673–694, ISSN 0007-8506. https://doi.org/10.1016/j.cirp.2013.05.004

    Article  Google Scholar 

  3. Westhoff D (2015) Entwicklung und Qualifizierung eines Funktionselementes für das einseitige, vorlochfreie Fügen im Karosserierohbau; Dissertation, Universität Paderborn

  4. Grandt, J.: Blindnietgewindesysteme: Typen, Verarbeitung, Einsatzbereiche. Die Bibliothek der Technik Bd. 159; Verlag Moderne Industrie, Landsberg/Lech, 1998

  5. Larson J (2008) Projection welding for nut and bolt attachment—competeting or complementary joining methods?; The fabricatur, Febuary 2008, p 55–57

  6. Larsson JK, Bengtsson L (2007) “The overlooked joining technology of fasteners for modern car body structures—latest experience from nut and bolt attachment to advanced high strength steels,” in proceedings from 11th European automotive Engineers' Council (EAEC), Budapest, May–June

  7. Miller WS, Zhuang L, Bottema J, Wittebrood AJ, De Smet P, Haszler A, Vieregge A (2000) Recent development in aluminium alloys for the automotive industry. Mater Sci Eng: A 280(1):37–49

    Article  Google Scholar 

  8. Szlosarek R, Karall T, Enzinger N, Hahne C, Meyer N (2013) Mechanical testing of flow drill screw joints between fibre-reinforced plastics and metals. Mater Test 55(10):737–742. https://doi.org/10.3139/120.110495

    Article  Google Scholar 

  9. Draht T (2006) Entwicklung des Bolzensetzens für Blech-Profil-Verbindungen im Fahrzeugbau. Dissertation, Universität Paderborn, Shaker Verlag, Aachen

  10. Flüggen F (2014) Qualifizierung des Bolzensetzens als Verfahren zum Fügen höchstfester Stahlwerkstoffe; Dissertation, Universität Paderborn

  11. Möhring J (2011) Qualifizierung von Fügeelementbeschichtungen für den Einsatz des druckluftbetriebenen Bolzensetzens im Karosseriebau, Dissertation, Universität Paderborn

  12. DIN 8580 (2003) Fertigungsverfahren - Begriffe, Einteilung, Beuth Verlag, Berlin

  13. DIN 8593–5 (2003) Fertigungsverfahren Fügen - Teil 5: Fügen durch Umformen; Einordnung, Unterteilung, Begriffe; Beuth Verlag, Berlin

  14. Hahn O, Klemens U (1996) Fügen durch Umformen, Nieten und Durchsetzfügen – Innovative Verbindungsverfahren für die Praxis. Dokumentation 707 der Studiengesellschaft Stahlanwendung e.V.; Düsseldorf

  15. Heimlich F (2008) Beitrag zum Einsatz von Aluminium-Funktionselementen in Leichtbauwerkstoffen; D466 Dissertation Universität Paderborn; Shaker Verlag Aachen

  16. N.N.: Merkblatt DVS®/EFB 3440–1 (2006) Funktionselemente Überblick. Merkblatt des DVS/EFB-Gemeinschaftsausschusses „Mechanisches Fügen“, DVS-Verlag, Düsseldorf

  17. Bye C (2006) Erweiterung des Einsatzfeldes von loch- und gewindeformenden Dünnblechschrauben zum Verbinden von Aluminiumhalbzeugen; Dissertation, Universität Paderborn

  18. Somasundaram S (2009) Experimentelle und numerische Untersuchungen des Tragverhaltens von Fließformschraubver-bindungen für crashbelastete Fahrzeugstrukturen; Dissertation, Universität Paderborn

  19. Kohl D (2014) Entwicklung und Qualifizierung eines Qualitätsprüfkonzeptes für das Hochgeschwindigkeits-Fügeverfahren Bolzensetzen im Automobil-Leichtbau, Dissertation, Universität Paderborn

  20. Hahn O, Meschut G, Nagel P, Flüggen F (2013) Eignung von loch- und gewindeformenden Schrauben zum Fügen von Mehrblechverbindungen. Öffentlicher Abschlussbericht zum gleichnamigen Forschungsvorhaben (EFB-Nr.: 07/209; IGFNr.: 16.694 N), Europäische Forschungsgesellschaft für Blechverarbeitung e.V., Hannover

  21. DIN EN 515 (1993) Aluminium und Aluminiumlegierungen – Halbzeug – Bezeichnung der Werkstoffzustände; Deutsche Fassung EN 515:1993; Beuth Verlag, Berlin

  22. DIN EN 573–3 (2013) Aluminium und Aluminiumlegierungen – Chemische Zusammensetzung und Form von Halbzeug – Teil 3: Chemische Zusammensetzung und Erzeugnisformen; Deutsche Fassung EN 573–3:2013; Beuth Verlag, Berlin

  23. Bender H, Schmale H-C (2015) Launch and quality optimization of bonding processes for mixed material designs in high volume production; Joining in Car Body Engineering, Bad Nauheim, 24.-25 März 2015

  24. N.N.: Merkblatt DVS®/EFB 3480–1 (2006) Prüfung von Verbindungseigenschaften – Prüfung der Eigenschaften mechanisch und kombiniert mittels Kleben gefertigter Verbindungen. Merkblatt des DVS/EFB Gemeinschaftsausschusses, DVS-Verlag, Düsseldorf

  25. Voce E (1955) A practical strain-hardening function. Meta 51:219–226

    Google Scholar 

  26. Hockett JE, Sherby OD (1975) Large strain deformation of polycrystalline metals at low homologous temperatures. J Mech Phys Solids 23(2):87–98, ISSN 0022-5096. https://doi.org/10.1016/0022-5096(75)90018-6

    Article  Google Scholar 

  27. Cockroft MG, Latham DJ (1968) Ductility and workability of metals. J Inst Met 96:33

    Google Scholar 

  28. Lee HC, Choi JS, Jung KH, Im YT (2009) Application of element deletion method for numerical analyses of cracking. J Achiev Mater Manuf Eng 2:154–161

    Google Scholar 

Download references

Acknowledgments

In this paper, selected results of the funded research projects IGF No.: 17807 N (EFB No.: 06-209) were presented. The IGF project IGF No.: 17807 N (EFB No.: 06-209) of the Europäischen Forschungsgesellschaft für Blechverarbeitung e. V. was promoted through the AiF under the program for the promotion of joint industrial research and development (IGF) by the Federal Ministry of Economics and Energy due to a resolution of the German Bundestag.

Author information

Authors and Affiliations

  1. Laboratory for Material and Joining Technology (LWF), University of Paderborn, Paderborn, Germany

    Philipp Nagel & Gerson Meschut

Authors
  1. Philipp Nagel
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Gerson Meschut
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Philipp Nagel.

Additional information

Recommended for publication by Select Committee AUTO - Automotive and Road Transport

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Nagel, P., Meschut, G. Combining a high-speed mechanical joining technique with the attachment of functional elements in automotive structures. Weld World 62, 215–225 (2018). https://doi.org/10.1007/s40194-017-0528-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40194-017-0528-8

Keywords

Search

Navigation