Value Through Solutions

Transcription

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2 2 The information contained within this presentation is intended solely as a guide for the customers of Semblex Corporation. This information may not be copied or distributed beyond the initial audience and organization it was presented to without the written consent of Semblex Corporation.

3 3 Founded in 1968 Manufacturer in Elmhurst, IL 250+ Team Members Focus in delivering Solutions to our Customer s Products Lightweighting Solutions.... ALtracs Plus SHEETracs

4 4 What is FDS FDS = Flow-Drill Screw Combines flow drilling and thread forming technologies into a single fastener design Used in high strength, multilayer sheet joints (aluminum, steel, etc.) Parts are driven with high speed and axial load, generating friction and heat, which promotes material flow and ease of thread forming.

5 Features of the FDS Screw 5 Any head style (internal or external) Undercut (optional) Usable thread length Thread forming zone Flowdrilling section Point (tip) of the screw

6 Benefits of Using FDS 6 Single sided assembly with no back support. Good for fastening into profiles/extrusions or tight spaces. Part preparation such as pre-drilling or pre-punching can be avoided. This eliminates alignment challenges and material waste.

7 7 Benefits of Using FDS Can be used in combination with structural adhesives for enhanced joint performance. Drive system (head style) can be tailored to meet customer s preferences or needs

8 8 Stages of the FDS Assembly without clearance hole Warming up the sheet metal by axial end load and high speed 2. Penetration into the material 3. Forming of the extrusion 4. Chipless forming of a female machine thread Installation 6. Tightening with the pre-set torque = Down-holder (Pressure foot)

9 FDS Assembly Animation 9

10 FDS Assembly Video 10 Courtesy of COMAU

11 11 FDS Examples in Aluminum without Clearance hole EN AW-6063 t=1,2mm EN AW-6063 t=3,0mm EN AW-6063 t=2,0mm EN AW-6063 t=3,0mm

12 12 Stages of the FDS Assembly with clearance hole 1. Warming up the sheet metal by axial end load and high speed Penetration into the material 3. Forming of the extrusion 4. Chipless forming of a female machine thread Installation 6. Tightening with the pre-set torque

13 13 FDS Example in Aluminum With Clearance Hole EN AW-6063 t=1,5mm EN AW-6063 t=4,0mm

14 14 Layer Stacking Strategy without Clearance Holes Fastening direction Clamped part (without clearence hole) 1) Thin on Thick Installation part 2) Soft on Hard Prevents Deflection and Maintains Joint Integrity

15 Application Materials and Thickness 15 Common Guidelines: Aluminum: Up to 5.0mm - Commonly 6000 series Steel: Up to 1.5mm (600 MPa max. tensile) - Can go thicker in softer steels - Can go harder in thinner steels Magnesium: Up to 4.0mm

16 16 Application Stack Examples (2T)

17 17 Application Stack Examples (3T)

18 FDS Material and Heat Treatment 18 Aluminum Applications Neutral hardened or case hardened steel Steel or Mixed (Steel & Aluminum) Applications Case hardened steel is required

19 FDS Coatings and Platings 19 Aluminum Applications Zinc flake coatings with optional topcoats Steel or Mixed (Steel & Aluminum) Applications Zinc or zinc-nickel with passivation Note: Additional lubrication is avoided in most applications to ensure adhesion of cataphoresic painting.

20 FDS Installation Speed 20 Aluminum Applications 4,000 RPM or greater (the faster the better) Steel or Mixed (Steel & Aluminum) Applications 2,000-2,500 RPM

21 FDS Repair Strategies 21 Drive one size larger FDS (M6 for an M5) with PKS point style. Special installation equipment not required. Drill and install thread forming screw. Drill, tap, and install machine screw.

22 22 Application Example: Audi TT Coupe/Roadster 229 FDS M5 screws Aluminum Profile Thicknesses: mm Aluminum Diecast Thickness: Up to 3mm 80% assembled into Aluminum Profile 75% in combination with adhesive source: Audi AG / EJOT

23 23 Application Example: Porsche 911/Boxster 190 FDS M5 screws Aluminum Profile Thicknesses: mm Aluminum Die Cast Thickness: Up to 3.0mm source: Porsche AG / EJOT

24 24 Application Example: Audi R8 310 FDS M5 screws Aluminum Profile Thicknesses: mm Aluminum Die Cast Thicknesses: Up to 3.0mm Max. Clamped Part Thickness 1.1 mm source: Audi AG / EJOT

25 25 Application Example: Audi A8 (D4) 640 FDS M5 screws Aluminum Profile Thicknesses: mm Aluminum Die Cast Thicknesses: Up to 3.5mm 18 assemblies with 3 layers source: Audi AG / EJOT

26 26 Application Example: Audi Q7 480 FDS M5 screws Aluminum Profile Thicknesses: mm Aluminum Die Cast Thicknesses: Up to 3.5mm source: Audi AG / EJOT

27 27 Application Example: Lamborghini Huracan 34 FDS M5 screws Aluminum Profile Thicknesses: 2.5mm Clamped Part Carbon-Fiber-Reinforced Polymer (CFRP) With Clearance Holes Thickness: 2.2mm source: EJOT

28 28 FDS at Semblex Current Program Support Ford 2015 F-150 (~150 per vehicle) GM Corvette (Z06) (~300 per vehicle) Other customer projects in process

29 29 Thank You Please visit us in the Exhibition Area