Eckold Clinching. The joining technique of the future. Clinching technology Product program Drives Quality monitoring References

Transcription

1 Eckold Clinching The joining technique of the future Clinching technology Product program Drives Quality monitoring References for sheet metal and profiles

2 Eckold Clinching is where the future of joining technology begins. Starting with this catalogue the method known as press joining will now be referred to as clinching. Eckold clinching is the innovative and proven technique for joining metal sheets and profiles. The permanent joints are created by cold forming alone, without the use of additional or ancillary parts. The most significant feature of this technique, which is established in the DIN 8593 standard, is that the joint is formed from the material of the metal parts to be clinched. Not only that, the parts to be clinched can be of the same or differing sheet thickness and be made from the same or different materials. The requirements of joints are so diverse that Eckold takes the individual requirements of the user into account. Eckold offers an unsurpassed diversity of joint types in order to allow the ideal clinch to be made for the respective application. Eckold clinching has proven its worth both in use in automatic production lines or with robots and with portable tooling. Clinching of oil-impregnated or painted panels or stainless steels and its ability to cope with fluctuations in sheet thickness are only a few of the advantages that have helped Eckold establish a prominent position in the market. In addition, Eckold offers a joining technique with which metal panels of aluminium alloys or non-malleable materials such as spring steels can be joined to malleable materials. Furthermore, Eckold clinching has special advantages with respect to the environment. No toxic welding vapours or emissions, no noise pollution and low energy consumption present the user with improved working conditions. In comparison with conventional joining techniques, the Eckold clinching offers a saving of up to 55% for investment costs and 25% for operating costs. Technologically, Eckold has remained true to its reputation as a trend-setter. Not only did Eckold introduce the clinching technique to industry 25 years ago, the company more recently set a new milestone with the economical clinching of stainless steels, thus continuing progress for joining technology of the future. 2

3 The basis of our success is our extensive product range starting with a widely varied tool programme through to a comprehensive range of standard machines and complete production systems: Portable Tools CONECO 45/60 easily portable, mobile, electric, electrohydraulic, hydraulic or pneumatic driven tools Modular C-frame range modular construction C-frame for mobile or stationary use MZD 60/6 mobile tool with adjustable fixed stop and large jaw capacity 3

4 Multipoint tooling Multipoint tooling for use in presses Stationary machines DFG 500/80 E universal machines, large throath, electrically driven Special installation Automatic production systems 4

5 The Benefits of Eckold Clinching. Eckold Clinching stands out from other joining techniques as a result of the following benefits: no thermal effects on the clinch area no toxic gases or vapours arising no preservative afterwork no additional or ancillary parts no pre-treatment of surface technique compensates for fluctuations in sheet thickness also suitable for joining coated sheets electricity or compressed air are the only energy sources required suitable for joining sheets of different materials and thicknesses non-destructive quality assurance possible Examples Engine bonnet motor car Casing for laboratory or domestic appliances Window opener car door Flow safety device gas heating appliance 5

6 An unsurpassed range of variations for individual problems. The principle of Eckold Clinching: diagram showing how a clinching element is created, taking R-DF as an example Stempel Punch Blech, Panel, punch-side stempelseitig Clinching element Fügeelement Blech, Panel, matrizenseitig die-side Matrize Die R The wide range of variations and the tool concept allows you to choose the right type of joint for your purposes. CLINCHING R-DF S-DF H-DF CONFIX clinch Cutting of sheet neither sheet both sheets one sheet one sheet with cut cut cut prepunched round hole Geometry of clinching element round rectangular rectangular round Benefits / particular applications - circular, closed element - high economy tools - high economy tools - circular element with = visually better - anti-twist element - anti-twist element flush finish on die side - high-strenght - also suitable for - high holding forces = visually better clinching element clinching more than - element ist closed - symmetry of shear tension - symmetry of shear two sheets on punch side holding forces tension holding forces - beneficial when - for clinching pairs of - particularly clinching sheets materials with beneficial when with different difficult to form material clinching sheets with forming behaviour on die side (spring steel) different forming behaviour (e.g. steel/aluminium) - clinching of sheets with (e.g. steel/aluminium or different steel/sandwich) thicknesses - high holding forces (e.g. 1.0 mm in 4.0 mm) Possible tool Die-side element Anvil diameter Punch width S punch width design diameter depending on pre-punched hole diameter [Tw = twin element] 6 mm 8 mm 10 mm 2 mm 3 mm 4 mm Tw 3 mm 4 mm Tw 5 mm 6 mm Possible individual sheet thicknesses [mm] punch side: Possible overall sheet thickness [mm] to be checked in each case Tool life quantities: The tool life quantities of the clinching tools can be in the order of to clinching operations. Customers confirm from tests and typical actual cases that far greater tool life quantities have been achieved, dependant on the material, the thickness and the quality. 6

7 Effect of load direction on the holding force of different joints Holding force [N] St12 / St14 / sheet thickness a 0 = 1.0 mm cross tension shear tension, longitudinal shear tension, transverse 1000 R-DF H-DF R-DF CONFIX Holding forces of R-DF elements Sheet material Sheet thickness Sheet thickness Tensile strength Holding force punch side die side Rm Shear Cross tension tension [mm] [mm] [N/mm 2 ] [N] [N] R-DF 8 element St 12/St AIMg3 W R-DF 6 element St 12/St AIMg3 F Holding forces of S-DF elements Sheet material Sheet thickness Sheet thickness Tensile strength Holding force punch side die side Rm Shear tension Shear tension Cross tension transverse longitudinal [mm] [mm] [N/mm 2 ] [N] [N] [N] St AIMg3 F Holding forces of H-DF elements Sheet material Sheet thickness Sheet thickness Tensile strength Holding force punch side die side Rm Shear tension Shear tension Cross tension transverse longitudinal [mm] [mm] [N/mm 2 ] [N] [N] [N] St 12 / St Holding forces of CONFIX clinches Sheet material Sheet material Sheet thickness Sheet thickness Tensile strength Holding force punch side die side punch side die side punch side Shear tension Cross tension [mm] [mm] [N/mm 2 ] [N] [N] St 1203 St St 1203 Federstahl

8 Many Benefits at low cost. Economic viability and costs Cost comparisons of customers and independent bodies have shown that Eckold clinching is significantly more cost-effective than other joining techniques. Depending on the joining task, the overall costs for the manufacture of a clinched component are approximately 55% of the costs for spot welding, for example. This takes account of both investment costs and operating costs. Clinching Investment costs in [%] Operating costs in [%] 100 [%] Spot welding 55.8 Investment costs in [%] Operating costs in [%] Clinching costs Sheet steel uncoated Sheet steel zinc thickness 10 µm 44.2 Comparison based on 1 industrial robot for setting a joining element Sheet steel Sheet aluminium zinc thickness 20 µm Why Eckold clinching? Various stainless steels can be joined economically Optional versions (R-DF, S-DF, H-DF and CONFIX) for the ideal joint to solve individual problems Sheets of aluminium alloys or non-formable materials such as spring steels can be joined with a formable material by means of the CONFIX variation Joining elements with the greatest holding forces Compensates for fluctuations in sheet thickness Joining of oil-impregnated sheets possible 8

9 Ecology and Health If you have ever experienced the smell of the toxic gases that arise during welding or the noise of punch riveting or had to physically carry the additional weight of protective clothing or additional materials, you will appreciate the benefits of Eckold clinching. This takes account of the user s health in many respects. Besides the significantly lower physical stresses, Eckold clinching is distinguished by low energy consumption and no industrial effluents whatsoever are generated. All in all, the Eckold technique is a clean and user friendly process. Quality control A manual method and a computer-aided online monitoring system can be used for quality control of Eckold clinching. The quality of the clinch element can be examined manually by means of the bottom thickness or width. 100% control is provided by the computer-aided online monitoring system. This can be used to achieve unbroken quality control in automatic plants for mass production. Production becomes more efficient and cost effective because down time and rejection rates are reduced through early detection of load errors. Clinching force Envelope curve top Envelope curve bottom Tool travel 9

10 Power sources for every application. Hydraulic, air over oil, electric and electrohydraulic drive units from the Eckold company are available to drive Eckold clinching machines. Below are three standard units which, depending on the application, can be supplemented with special units that are also available in stationary versions. Drives HAT 525 portable hydraulic unit HA 510 mobile hydraulic unit Antriebsarten elektrisch hydraulisch pneumohydraulisch 10

11 Eckold is available for you worldwide. Increasing in importance alongside the standard products are special tools, project organisation and design of special tools, machines and installations. Thanks to our years of experience, including the solving of particularly complex customer requirements, we are well equipped to move into this area. In close collaboration with you, our customer, we plan, design and produce for any location you wish. Our involvement does not stop at that either - the subsequent training of operating staff, the maintenance of machines and the worldwide service are a natural step for us. To cope with this demand - all over the world - we have established a widely distributed network of representatives. Eckold production plants are of course certified to ISO 9001:2000 as well as VDA 6.4:2005. Further information is available on our CD-ROM and in our Clinching manual, which we would be pleased to send you. Weitere Informationen finden Sie auf unserer CD-ROM und in unserem Leitfaden Clinchtechnik, welche wir Ihnen gerne zusenden. 11

12 The Eckold Group Eckold GmbH & Co. KG D St. Andreasberg Germany Tel.: (55 82) Fax: (55 82) Net: info@eckold.de Eckold-Biegetechnik GmbH & Co. KG D St. Andreasberg Germany Tel.: (55 82) Fax: (55 82) biegetechnik@eckold.de Eckold AG Rheinstraße CH-7203 Trimmis Switzerland Tel.: (81) Fax: (81) Net: info@eckold.ch Eckold Limited 15 Lifford Way Binley Industrial Estate GB-Coventry CV3 2RN Great Britain Tel.: (24) Fax: (24) sales@eckold.co.uk Eckold France 16, Rue de la Noue Guimante Z.I. de la Courtillière F St. Thibault-des-Vignes France Tel.: (1) Fax: (1) Net: info@eckold.fr Eckold & Vavrouch spol. s.r.o. Jilemnickeho 8 CZ Brno Czech Republic Tel.: (5) Fax: (5) Net: eckold@volny.cz Eckold Japan Co. Ltd Maihara-higashi Funabashi-shi, Chiba pref. Japan Tel.: (47) Fax: (47) Net: info@eckold.co.jp Printed in Germany 002/09.08/4/500/D/Kohlmann Technische Änderungen vorbehalten/technical modifications kept under reserve.