WEB Process Integrated Manufacture of Adaptive Friction-Spun Joint Connectors (FSJC)Tuesday (22.09.2020) 15:40 - 15:55 Z: Special Symposia II Part of:
Present-day lightweight design frequently requires adapted wall thicknesses and highly diversified material combinations within a product. Mechanical joining techniques are often used by way of a joining technology for the different materials and part thicknesses. Mechanical joining techniques, however, need to be specifically adapted to the properties of the joint in respect of the geometry and dimensions of the auxiliary joining part. This paper presents a new mechanical joining process that can bond a wide range of sheet materials employing an adjustable FSJC. The part geometry required for the properties of a given joint is formed by a friction spinning process using a universal forming tool. This makes it possible to form a wide variety of sub-geometries on the auxiliary joining part, depending on the prevailing condition of the joint, with a single forming tool. By applying different process strategies for rotational speed and feed rate during the forming process, the same part geometry can even display dissimilar local mechanical properties and be adapted to the requirements of the joint properties to an even greater extent. The connectors are formed on the end of an (endless) wire or tubular semi-finished bar material. Separation of the auxiliary joining part is thus no longer necessary, saving on the handling and positioning of these small parts. The joint connector remains fixed in the clamping chuck until the joint setting process has been completed. The setting process involves the friction-spinning technique as well as the forming operation beforehand. This innovative joining process makes it possible to bond a wide range of joint components that differ in terms of thickness, geometry and material, employing the same starting product and joining process and individualized joint connectors. This joining solution thus constitutes a cost-efficient process for joining tailored parts and will significantly increase design flexibility.