The challenge was the joining of a non-typical geometry like a bracket with a second part. Joining a shaft to a bracket, holding parts together was only possible by cutting a thread and installing a nut. An alternative would be welding.
Both joining methods are expensive and inherently disadvantageous (welding means heat). At the same time, the geometry of the part does not really allow forming of material.
The shaft of the "rivet" was designed in a way that "shear riveting" would become possible. It included the work of piece modification (increased hole diameter) and producing a new forming tool. Thanks to a special forming tool (with appropriate coating for a long service life), the parts could be joined with minimal forming force. There was no deformation of the component. Forming time also is minimal. The effort to implement this change was easily realized at a cost not worth mentioning.
Facts & Figures
|Riveting Process||Radial riveting|
|Geometry||Ø: OD 3.2mm / ID 2.5mm|
|Shank type||Solid shaft with a step|
|Rivet head geometry||Clinched|
|Forming Tool||Hollow forming tool with a cutting edge|
|Performance Data||Cycle time: approx.1.3 sec, TDC-TDC|
|Devices||Standard machine RN181, downholder is recommended|
|Process Control||With or without process monitoring possible|
|Area of Application||Automotive, general industry, white goods, precision industry, miniature components|
|Benefits of change of process||Highly reliable process. When using process monitoring, there is 100% in-process quality control without additional effort.|
|User Benefits: Process||Reduced effort when setting up or changing over the production line. Shorter cycle time, reliable process, and no undesired part deformation.|
|User Benefits: Economic||Significantly lower investment costs (no additional handling devices and feeders needed) and massively reduced TCO.|