RB&W GLOBAL LIGHTWEIGHT MATERIAL PRESENTATION April 14, 2015 SPAC Applications 1
Global Market Trend CO2 Emission Fuel Efficiency Vehicle Weight Reduction INCREASED USAGE High Strength Steels Aluminum Magnesium Composites
SOLUTION: PIERCE AND CLINCH FASTENING
Pierce and Clinch Video
PIERCE and CLINCH BENEFITS Mass Reduction in Joint Compact Packaging Property Class 10 Elimination of Secondary Operations Nut Center to Center Tolerance 0.2mm
WEIGHT (MASS) CAN BE SAVED BY USING OEM SPAC NUT TECHNOLOGY Vs PC10 FLANGE WELD NUT TECHNOLOGY 1. SPAC NUT MASS REDUCTION BENEFITS: A. LOW BODY PROFILE B. PC10 HEAT TREATED MATERIAL STRENGTH C. A PORTION OF THE INTERNAL THREAD ENGAGEMENT IS POSITIONED WITHIN THE PRESSING D. THE MATING SCREW SHANK LENGTH CAN BE REDUCED BY AN AMOUNT EQUIVALENT TO THE PRESSING THICKNESS 2. THE WEIGHT / MASS BENEFIT ASSOCIATED WITH USING AN OEM HGL-Lt SPAC NUT VERSUS A FLANGE WELD NUT OF SIMILAR PC10 STRENGTH LEVEL CAN BE READILY DEMONSTRATED; BY DOING SO, BY PRODUCT THREAD SIZE, THE MASS BENEFIT OF THE SPAC NUT IS CLEARLY VISIBLE. 10 10 10 10 10 M6 THREAD SIZE M8 THREAD SIZE M10 THREAD SIZE M12 THREAD SIZE M14 THREAD SIZE
Packaging Reduction SPAC Nut JOINT Flange Weld Nut JOINT Base Material Thickness Less Mass within the Joint Lighter Nut (SPAC Nut vs. Flange Weld Nut) Shorter Mating Bolt in Joint with SPAC Nut s Base Material replaced by the SPAC Nut s Punch
LOWER MANUFACTURING COSTS
HIGH STRENGTH STEELS and HOT STAMPED MATERIALS SPAC Applications 9
HIGH STRENGTH / HOT-STAMPED 980-1700 MPa MATERIAL TYPES : Hot Stamped 1300 to 1600 Cold Rolled 980 Mpa J 2340 1300-1500 J 2340 800DL-1300DL Usibor 1500 M 190 MBW 1500 MBW 1900 DOCOL 1000/1200
GOAL: LIMIT MICRO CRACKING PROPOGATION IN WORKPIECE PIERCE METHOD: NO Pre-pierced or laser cut hole required for SPAC Nut installation 1 time use, single direction pierce is created thru SPAC RESULT: Testing was conducted to investigate the pattern and magnitude of the Residual Stresses within Hot-Stamping Materials. Test results show the test coupons with an installed SPAC Nut were in a state of compression. A compressive state is desirable since cracks cannot be propagated.
Torque Out Mean (Nm) HIGH STRENGTH MATERIAL 160 140 142.2 120 100 102.9 106.1 80 79.3 60 40 20 42.4 29.6 1100 MATERIAL 1420 MATERIAL 0 M6 M8 M10
Hot Stamped 1300 Mpa tensile strength material Fastener close to radius Issues with weld nuts cold welds & weld arcing at stamping radius Micro-crack potential with pre-pierced or laser cut holes
Hot Stamped Structural Beam - Usibor 1500-1.2 mm thick - 20 Ton setting force
HOT STAMPING Insert SPAC in die - Eliminate secondary operation - No laser cutting - Material structural integrity unchanged - True product position achieved 950 C (1700 F) 150 C (300 F) INSERT PIERCE Nut During the forming and dwell time 0 >>Dwell at BDC Seconds>> 10
Roll Form Section 2 nd Row Seat Cross Member 1.0mm thick M-190-1300MPa material Unable to use traditional weld nut process No access to install fastener after rolling Fastener close to bend radius Eliminated secondary operation floor space requirement Tight nut to nut tolerance achieved.2mm center to center
ALUMINUM SPAC Applications 17
Torque Out Mean (Nm) 140.0 120.0 ALUMINUM 1mm-10mm Material Thickness 120.0 100.0 80.0 60.0 66.8 40.0 37.6 20.0 0.0 M6 M8 M10 18
Lightweight Material Challenges Torque Relaxation Typical joint compression zone Optimised bearing surface area for the joint (load, material). Material / component layers Bolt & Washer No additional washers required No loose components Low profile Light-weight Short bolt required Self pierce & clinch fasteners available with large bearing surface areas High clamp loads can be achieved Can be auto-fed in die / robotic cell
Side Impact Protection Aluminum 7075 T6
Manufacturing LLC LH (6)M8 SPAC NUTS LH (3) M6 SPAC NUTS
Manufacturing LLC (8) M8 SPAC NUTS (14) M6 SPAC NUTS
Crush Can / Crash Tube Brackets
SPAC NUT ADVANTAGES ALUMINUM CRUSH TUBES
ALUMINUM CASTINGS SPAC Applications 25
DESIGN OPTIONS RIVNUTS / INSERTS SPAC NUTS - Costly Machining Required - Locally embossed higher wall - Complex die design and cost - Low torque and high costs + No Embossment of material + No pre hole Required + True position accuracy + Exceptional torque performance Extra material, machining is needed to use threaded inserts. SUMMARY Reduced cycle times and lower fastener and die costs
CASE STUDY SHOCK TOWER 3 second process saving per fastener installation using SPAC over riv-nuts = 4363 hrs (180 days) $0.06/fastener saving = $315,000/year Hardware & capacity for new variants / new components Offset tooling Total Volume / annum M6 = 3.6 million M8 = 372 thousand M10 = 1.2 million Total Sales / annum = $600,000 27
TYPICAL CURRENT APPLICATIONS Wiper Bracket Front End Bumper Attachment Casting 2 x M10 (M14 Body) Swan neck casting 3 x M12 for 2nd row seat attachments. Transmission Bracket (3) M10 Shock Tower (2)M10, M8, (6) M6 28
MAGNESIUM SPAC Applications 29
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FASTENING IN MAGNESIUM GALVANIC PROTECTION TRADITIONAL FASTENING DESIGN ALUMINUM PIERCE AND CLINCH NUT DESIGN ALUMINUM SELF PIERCE NUT MAGNESIUM DISSIMILAR METAL ALUMINUM HEX FLANGE BOLT 31
HIGH PERFORMANCE CRITICAL PIERCE NUT PRODUCT APPLICATIONS Cast Magnesium with Pierce Nuts JOINT CONSIDERATIONS Packaging constraints Costs and Time to machine holes Casting die complexity and cost for pre hole Inserting without cracking material Corrosion Magnesium Convertible 32
THANK YOU SPAC Applications 33