Mechanical joining

Innovative processes for lightweight construction and composite design#

Innovative joining processes are the basis for implementing sustainable component concepts. We develop processes, e.g. for joining of high-strength steels with light alloys based on aluminum, magnesium or titanium, and for joining of material combinations of metals and fiber-reinforced plastics. Another research focus lies on optimization of joining processes regarding quality, reproducibility as well as energy- and resource-efficiency. This includes the description of the entire production process for car body assembly groups using continuous experimental and numerical investigation of the process chain (forming, joining and lacquer drying).

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Clinching and riveting processes

Process combinations

Measuring and testing methods

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  • Cost-effective joining of same and different materials
  • Lightweight and composite construction: exploiting energy-efficient alternatives to resistance spot-welding and other thermal joining processes
  • Overcoming process limits and combining advantages by using hybrid joining processes (clinching, self-pierce riveting, adhesive bonding, hem flange bonding)
  • Specific optimization of process variables by simulation

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Process development

  • Market analysis
  • Investigation of process chain
  • Process optimization, sensitivity analyse, process reliability
  • Cost-benefit calculation
  • New and further development of joining processes:
  • Mechanical joining processes, especially for multi-material design
  • Hybrid joining processes with adhesive bonding
  • Planning and technological dimensioning of processes, tool and machine
  • Recommendations for investments regarding machines or technologies
  • Joining in press plants
  • Experimental and numerical simulation of process chains in joining
  • Tolerance analysis in process chains

Development and evaluation of mechanical joining strategies

  • Market analysis
  • Feasibility studies
  • Technology development
  • Development of process parameters and ideal forming strategies
  • Benchmarking
  • Numerical simulation, numerical simulation of structure
  • Manufacturing of prototypes
  • Analysis of joint formations (FE calculation and experiment)
  • Determination of the component behavior in thermal processes
  • Design of joints

Quality assurance

  • Process monitoring (pre-/in/post-process)
  • Inspection of assembly groups (quasi-static, cyclic and crash)
  • Testing the properties of joints and components
  • Development of testing methods
  • Climate test and corrosion tests

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Joining machines

  • Eckold MFG 005 (self-pierce riveting and clinching machine)
  • Eckold c-bracket-column machine DFG 500/10
  • Friedrich 35KN wobble press
  • Friedrich B3013 radial-point riveting system
  • Hilti test station
  • Kerb-Konus solid self-pierce riveting machine
  • Impulse riveting machine
  • Promess 320
  • Promess 350/180
  • Promess UFM 100/70/200Tox-Pressotechnik (solid riveting machine)
  • WEBER wobble-riveting system NEB 5510
  • DUNKES servo spindle press
  • Adhesive technology (SCA Schucker, Netzsch, Beyer&Otto)

Industrial robots

  • ABB IRB 660
  • KUKA KR 15
  • KUKA KR 150 R 2700 extra
  • KUKA VW Hemming robot

Inspection technology

  • DynaMess table-top testing machine
  • GOM (ARAMIS, PONTOS, ARGUS,
  •  TRITOP, ATOS)
  • Drop test stand Instron dynatup 8160
  • Drop test stand Instron dynatup 9250HV
  • Feutron double climatic chamber
  • (2-chamber process for differential climatic strain)
  • Hegewald & Peschke 50kN
  • Universal inspection machine
  • Hydropuls test stand INSTRON-IST
  • Koehler corrosion test chamberHK400
  •  (Salt spray test and condensation change test)
  • MAXIMATOR hydraulic unit
  • Universal inspection machine Inspekt desk 50
  • VÖTSCH heating and drying cabinet
  • VTU 150/150/20-200 °C

Sample preparation / metallography

  • Struers CitoPress-1
  • Struers Discotom-5
  • Struers Discotom-60
  • Struers ProntoPress-10
  • Struers TegraPol-11
  • Struers Tegramin-25

Software

  • ABAQUS
  • ANSYS
  • Autocad
  • CAD, CATIA
  • CREO / ProEngineer
  • DEFORM
  • Exceed / 3D_CSS
  • Fame tools
  • Fortran Compiler
  • Hypermesh
  • LSDYNA
  • Matlab, MathCad, Mathematika
  • National Instruments
  • OptiSLang
  • Origin
  • PAM-STAMP
  • Rapidform XOR
  • SolidWorks